Method for mechanical packaging for modular energy system

ABSTRACT

Disclosed is a method of assembling a backplane connector subassembly for a module of a modular energy system. The backplane connector subassembly physically and electrically connects at least two modules stacked on top of one another. The method includes providing a back panel defining an inner surface, attaching a first support member to the inner surface of the back panel, attaching a second support member to the inner surface of the back panel, attaching the upstream connector to the back panel by sliding a first mating hole defined in the upstream connector onto the first support member, and attaching the downstream connector to the back panel by a sliding a second mating hole defined in the downstream connector onto the second support member. The first support member is configured to support an upstream connector. The second support member is configured to support a downstream connector.

BACKGROUND

The present disclosure relates to various surgical systems, includingmodular electrosurgical and/or ultrasonic surgical systems. Operatingrooms (ORs) are in need of streamlined capital solutions because ORs area tangled web of cords, devices, and people due to the number ofdifferent devices that are needed to complete each surgical procedure.This is a reality of every OR in every market throughout the globe.Capital equipment is a major offender in creating clutter within ORsbecause most capital equipment performs one task or job, and each typeof capital equipment requires unique techniques or methods to use andhas a unique user interface. Accordingly, there are unmet consumer needsfor capital equipment and other surgical technology to be consolidatedin order to decrease the equipment footprint within the OR, streamlinethe equipment's interfaces, and improve surgical staff efficiency duringa surgical procedure by reducing the number of devices that surgicalstaff members need to interact with.

SUMMARY

In one general aspect, the present disclosure provides a method ofassembling a backplane connector subassembly for a module of a modularenergy system. The backplane connector subassembly physically andelectrically connects at least two modules stacked on top of oneanother. The method comprises providing a back panel defining an innersurface; attaching a first support member to the inner surface of theback panel, wherein the first support member is configured to support anupstream connector; attaching a second support member to the innersurface of the back panel, wherein the second support member isconfigured to support a downstream connector; attaching the upstreamconnector to the back panel by sliding a first mating hole defined inthe upstream connector onto the first support member; and attaching thedownstream connector to the back panel by a sliding a second mating holedefined in the downstream connector onto the second support member.

In one general aspect, the present disclosure provides a method ofassembling a backplane connector subassembly for a module of a modularenergy system. The backplane connector subassembly physically andelectrically connects at least two modules stacked on top of oneanother. The method comprises providing a back panel defining an innersurface; attaching a first set of two support members to the innersurface of the back panel, wherein the first set of two support membersis configured to support an upstream connector; attaching a second setof two support members to the inner surface of the back panel, whereinthe second set of two support members is configured to support adownstream connector; attaching the upstream connector to the back panelby sliding first and second mating holes defined in the upstreamconnector onto the first set of two support members; and attaching thedownstream connector to the back panel by a sliding first and secondmating holes defined in the downstream connector onto the second set oftwo support members.

In one general aspect, the present disclosure provides a method ofassembling a display assembly for a header module of a modular energysystem. The method comprises providing a rear enclosure defining arecess and a plurality of notches, forming a display sub-assembly bycoupling a touchscreen to a front cover, wherein the front covercomprises a plurality of latches, and releasably coupling the displaysub-assembly to the rear enclosure by positioning the plurality oflatches of the front cover in the plurality of notches of the rearenclosure.

In one general aspect, the present disclosure provides a modular energysystem that comprises a first module, comprising a first panel, and afirst connector attached to the first panel. A portion of the firstconnector extends past a first edge of the first panel. The modularenergy system further comprises a second module, comprising a secondpanel, and a second connector attached to the second panel. The secondconnector is aligned with a second edge of the second panel, and thesecond connector defines a cavity. The second module is coupled to thefirst module, wherein the portion of the first connector that extendspast the first edge of the first panel is positioned within the cavitydefined by the second connector.

In another aspect, the present disclosure provides a modular energysystem, comprising a first module. The first module comprises a firstpanel. The first panel comprises a first support member attached to thepanel, and a second support member attached to the panel, wherein thesecond support member is offset from the first support member. The firstpanel further comprises a support ledge attached to the first panel,wherein the support ledge is located between the first support memberand the second support member. The first module further comprises afirst connector, defining a first hole in the first connector. The firstconnector comprises a support rib that extends away from the firstconnector. The first connector is slidably attachable to the firstpanel, wherein the first support member is slidably insertable into thefirst hole. In the attached configuration, the support rib is configuredto rest against the support ledge. In the attached configuration, aportion of the first connector extends past a first edge of the firstpanel. The first module further comprises a second connector defining acavity and a second hole. The second connector is slidably attachable tothe first panel, wherein the second support member is slidablyreceivable into the second hole. In the attached configuration thesecond connector is aligned with a second edge of the first panel,wherein the second edge of the first panel is opposite the first edge ofthe first panel.

In another aspect, the present disclosure provides a module for amodular energy system, the module comprises a panel. The panel comprisesa first support member attached to and extending away from the panel, asecond support member attached to and extending away from the panel,wherein the second support member is offset from the first supportmember. The module further comprises a first connector defining a firsthole in the first connector. The first connector is slidably attachableto the panel, wherein the first support member is slidably receivableinto the first hole. In the attached configuration a portion of thefirst connector extends past a first edge of the panel. The modulefurther comprises a second connector defining a cavity and a secondhole. The second connector is slidably attachable to the first panel,wherein the second support member is slidably receivable into the secondhole. In the attached configuration the second connector is aligned witha second edge of the panel, and wherein the second edge of the firstpanel is opposite the first edge of the panel.

In yet another aspect, the present disclosure provides a modular energysystem that comprises a header module, wherein the header module isconfigured to supply power to one or more connected dependent modules.The a modular energy system further comprises at least one dependentmodule connected to the header module and powered by the header module,and a power module connected to the dependent module, wherein the powermodule is configured to supply power to one or more other connecteddependent modules.

In various aspects, a port module removably coupleable to an energymodule of a module energy system is disclosed. The port module includesa light pipe and a receptacle defined by the light pipe. The receptacleis configured to receive a plug of an electrosurgical instrumenttherein. A seal is defined between the light pipe and the receptacle.

In various aspects, an energy module of a module energy system isdisclosed. The energy module includes an enclosure defining a firstaperture, a control circuit positioned within the enclosure, a portmodule, and a light blocking insert. The control circuit defines asecond aperture aligned with the first aperture. The port module extendsthrough the first aperture and the second aperture. A gap is definedbetween the second aperture and the port module. The light blockinginsert is positioned in the gap.

In various aspects, an energy module of a module energy system isdisclosed. The energy module includes an enclosure defining a firstaperture, a control circuit positioned within the enclosure, a portmodule, and a light blocking insert. The control circuit defines asecond aperture aligned with the first aperture. The port module extendsthrough the first aperture and the second aperture. The port moduleincludes a light pipe and a receptacle. The receptacle is configured toreceive a plug of an electrosurgical instrument therein. A seal isdefined between the light pipe and the receptacle. A gap is definedbetween the second aperture and the port module. The light blockinginsert is positioned in the gap.

In various aspects, a modular energy system is disclosed. The modularenergy system includes a header module comprising an enclosure and adisplay comprising a coupler. The enclosure defines a recess. The recesscomprises a first guidewall and a second guidewall. The coupler isremovably positionable in the recess. The coupler comprises a firstsidewall, wherein the first guidewall is configured to guide the firstsidewall as the coupler moves through the recess, and a second sidewall,wherein the second guidewall is configured to guide the second sidewallas the coupler moves through the recess.

In various aspects, a modular energy system is disclosed. The modularenergy system includes a header module comprising an enclosure, adisplay comprising a coupler, and a latch mechanism configured toremovably latch the display to the header module. The enclosure definesa recess. The coupler is removably positionable in the recess.

In various aspects, a modular energy system is disclosed. The modularenergy system includes a header module comprising a housing and adisplay comprising a coupler. The housing defines a recess. The recesscomprises a first guidewall, a second guidewall angled relative to thefirst guidewall, and a first electrical connector. The coupler isremovably positionable in the recess. The coupler comprises a secondelectrical connector configured to removably couple to the firstelectrical connector, a first sidewall configured to move along thefirst guidewall, and a second sidewall configured to move along thesecond guidewall, wherein the first sidewall and the second sidewall areconfigured to guide the second electrical connector toward the firstelectrical connector.

FIGURES

The various aspects described herein, both as to organization andmethods of operation, together with further objects and advantagesthereof, may best be understood by reference to the followingdescription, taken in conjunction with the accompanying drawings asfollows.

FIG. 1 is a block diagram of a computer-implemented interactive surgicalsystem, in accordance with at least one aspect of the presentdisclosure.

FIG. 2 is a surgical system being used to perform a surgical procedurein an operating room, in accordance with at least one aspect of thepresent disclosure.

FIG. 3 is a surgical hub paired with a visualization system, a roboticsystem, and an intelligent instrument, in accordance with at least oneaspect of the present disclosure.

FIG. 4 is a surgical system comprising a generator and various surgicalinstruments usable therewith, in accordance with at least one aspect ofthe present disclosure.

FIG. 5 is a diagram of a situationally aware surgical system, inaccordance with at least one aspect of the present disclosure.

FIG. 6 is a diagram of various modules and other components that arecombinable to customize modular energy systems, in accordance with atleast one aspect of the present disclosure.

FIG. 7A is a first illustrative modular energy system configurationincluding a header module and a display screen that renders a graphicaluser interface (GUI) for relaying information regarding modulesconnected to the header module, in accordance with at least one aspectof the present disclosure.

FIG. 7B is the modular energy system shown in FIG. 7A mounted to a cart,in accordance with at least one aspect of the present disclosure.

FIG. 8A is a second illustrative modular energy system configurationincluding a header module, a display screen, an energy module, and anexpanded energy module connected together and mounted to a cart, inaccordance with at least one aspect of the present disclosure.

FIG. 8B is a third illustrative modular energy system configuration thatis similar to the second configuration shown in FIG. 7A, except that theheader module lacks a display screen, in accordance with at least oneaspect of the present disclosure.

FIG. 9 is a fourth illustrative modular energy system configurationincluding a header module, a display screen, an energy module, aeexpanded energy module, and a technology module connected together andmounted to a cart, in accordance with at least one aspect of the presentdisclosure.

FIG. 10 is a fifth illustrative modular energy system configurationincluding a header module, a display screen, an energy module, anexpanded energy module, a technology module, and a visualization moduleconnected together and mounted to a cart, in accordance with at leastone aspect of the present disclosure.

FIG. 11 is a diagram of a modular energy system including communicablyconnectable surgical platforms, in accordance with at least one aspectof the present disclosure.

FIG. 12 is a perspective view of a header module of a modular energysystem including a user interface, in accordance with at least oneaspect of the present disclosure.

FIG. 13 is a block diagram of a stand-alone hub configuration of amodular energy system, in accordance with at least one aspect of thepresent disclosure.

FIG. 14 is a block diagram of a hub configuration of a modular energysystem integrated with a surgical control system, in accordance with atleast one aspect of the present disclosure.

FIG. 15 is a schematic diagram of a modular energy system stackillustrating a power backplane, in accordance with at least one aspectof the present disclosure.

FIG. 16 is a schematic diagram of a modular energy system, in accordancewith at least one aspect of the present disclosure.

FIG. 17 is an exploded view of a backplane connector subassembly for amodule of a modular energy system, in accordance with at least oneaspect of the present disclosure.

FIG. 18 is an elevated view of a backplane connector subassembly for amodule of a modular energy system, in accordance with at least oneaspect of the present disclosure.

FIG. 19 is an elevated view of a panel of the backplane connectorsubassembly, in accordance with at least one aspect of the presentdisclosure.

FIG. 20 is an elevated view of an upstream connector for a backplaneconnector subassembly, in accordance with at least one aspect of thepresent disclosure.

FIG. 21 is an elevated view of a downstream connector for a backplaneconnector subassembly, in accordance with at least one aspect of thepresent disclosure.

FIG. 22 is a front view of a panel for a backplane connectorsubassembly, in accordance with at least one aspect of the presentdisclosure.

FIG. 23 is a front view of the panel for a backplane connectorsubassembly shown in FIG. 22 with the upstream and downstream connectorsattached, in accordance with at least one aspect of the presentdisclosure.

FIG. 24 is a back view of the panel shown in FIG. 23 with the upstreamand downstream connectors attached, in accordance with at least oneaspect of the present disclosure.

FIG. 25 is an elevated view of the backplane connector subassembly shownin FIG. 7 with connection wires added, in accordance with at least oneaspect of the present disclosure.

FIG. 26 is a front view of the backplane connector subassembly shown inFIG. 7 with connection wires added, in accordance with at least oneaspect of the present disclosure.

FIG. 27 is a side view of the upstream connector attached to the panelof the backplane subassembly, in accordance with at least one aspect ofthe present disclosure.

FIG. 28 is an elevated view of the backplane connector subassembly ofFIG. 9 with the circuit board added, in accordance with at least oneaspect of the present disclosure.

FIG. 29 is a front view of the backplane connector subassembly of FIG. 9with the circuit board added, in accordance with at least one aspect ofthe present disclosure.

FIG. 30 illustrates a modular energy system, in accordance with at leastone aspect of the present disclosure.

FIG. 31 illustrates various electrical connections in the modular energysystem of FIG. 30, in accordance with at least one aspect of the presentdisclosure.

FIG. 32 illustrates a module of the modular energy system of FIG. 30, inaccordance with at least one aspect of the present disclosure.

FIG. 33 illustrates a module of a modular energy system, which includesa rigid wire harness, in accordance with at least one aspect of thepresent disclosure, in accordance with at least one aspect of thepresent disclosure.

FIG. 34 is an elevated view of the backplane connector subassemblyshowing the connection wires as wire ribbons, in accordance with atleast one aspect of the present disclosure.

FIG. 35 is a side view of a method to connect the upstream connector tothe panel of the backplane subassembly, in accordance with at least oneaspect of the present disclosure.

FIG. 36 is a side view of a method to connect the downstream connectorto the panel of the backplane subassembly, in accordance with at leastone aspect of the present disclosure.

FIG. 37A is an elevated view of a method to connect the upstream anddownstream connectors to a panel for the backplane connectorsubassembly, in accordance with at least one aspect of the presentdisclosure.

FIG. 37B is an elevated view of a method to connect the upstream anddownstream connectors to a panel for the backplane connectorsubassembly, in accordance with at least one aspect of the presentdisclosure.

FIG. 37C is an elevated view of a method to connect the upstream anddownstream connectors to a panel for the backplane connectorsubassembly, in accordance with at least one aspect of the presentdisclosure.

FIG. 38 is an elevated view of a cartridge system to allow a backplaneconnector to be connected to a module, in accordance with at least oneaspect of the present disclosure.

FIG. 39 is an elevated view of a backplane connector that snaps into thebottom of the module enclosure, in accordance with at least one aspectof the present disclosure.

FIG. 40 is a front view of a backplane connector subassembly that isbuilt into a module enclosure, in accordance with at least one aspect ofthe present disclosure.

FIG. 41 is a bottom view of the upstream connector shown in FIG. 18, inaccordance with at least one aspect of the present disclosure.

FIG. 42 is a front view of a backplane connector subassembly that isbuilt into a module enclosure, in accordance with at least one aspect ofthe present disclosure.

FIG. 43 illustrates a modular energy system that contains a powermodule, in accordance with at least one aspect of the presentdisclosure.

FIG. 44 illustrates a port module, according to at least one aspect ofthe present disclosure.

FIG. 45 illustrates another port module, according to at least oneaspect of the present disclosure.

FIG. 46 illustrates a cross-section view of the port module of FIG. 44,according to at least one aspect of the present disclosure.

FIG. 47 illustrates another cross-section view of a port module of FIG.44 and illustrates mechanical engagement features, according to at leastone aspect of the present disclosure.

FIG. 48 illustrates an isometric view of the port module of FIG. 44,according to at least one aspect of the present disclosure.

FIG. 49 illustrates a rear view of a header module that includes aplurality or port modules and a control circuit, according to at leastone aspect of the present disclosure.

FIG. 50 illustrates the rear view of FIG. 49 with the control circuitremoved, according to at least one aspect of the present disclosure.

FIG. 51 illustrates an isometric view of FIG. 49, according to at leastone aspect of the present disclosure.

FIG. 52 illustrates the isometric view of FIG. 49 with the port modulesremoved, according to at least one aspect of the present disclosure.

FIG. 53 illustrates an isometric view of a port module coupled to aheader module, according to at least one aspect of the presentdisclosure.

FIG. 54 illustrates a side view of FIG. 53, according to at least oneaspect of the present disclosure.

FIG. 55 illustrates a light blocking insert, according to at least oneaspect of the present disclosure.

FIG. 56 illustrates a header module that includes two port modules, onewith a light blocking insert therearound and one without a lightblocking insert, according to at least one aspect of the presentdisclosure.

FIG. 57 illustrates a header module that includes a plurality of portmodules that have light blocking inserts, according to at least oneaspect of the present disclosure.

FIG. 58 illustrates the header module of FIG. 57 with the light blockinginserts removed, according to at least one aspect of the presentdisclosure.

FIG. 59 illustrates an energy module including angled vents, accordingto at least one aspect of the present disclosure.

FIG. 60 illustrates a cross-sectional view of the energy module of FIG.59 with the angled vents, according to at least one aspect of thepresent disclosure.

FIG. 61 illustrates a sidewall of an energy module including angledvents, according to at least one aspect of the present disclosure.

FIG. 62 illustrates a side view of an energy module including angledvents, according to at least one aspect of the present disclosure.

FIG. 63 illustrates a rear view of the energy module of FIG. 62,according to at least one aspect of the present disclosure.

FIG. 64 illustrates a close-up view of the angled vents of the energymodule of 62, according to at least one aspect of the presentdisclosure.

FIG. 65 illustrates a containment structure, according to at least oneaspect of the present disclosure.

FIG. 66 illustrates a modular energy system, according to at least oneaspect of the present disclosure.

FIG. 67 illustrates an exploded view of the modular energy system ofFIG. 67, according to at least one aspect of the present disclosure.

FIG. 68 illustrates a display uncoupled from a header module of themodular energy system, according to at least one aspect of the presentdisclosure.

FIG. 69 illustrates a display coupled to a header module of the modularenergy system, according to at least one aspect of the presentdisclosure.

FIG. 70 illustrates a latch mechanism in a locked position, according toat least one aspect of the present disclosure.

FIG. 71 illustrates the latch mechanism of FIG. 70 in an unlockedposition, according to at least one aspect of the present disclosure.

FIG. 72 illustrates a mounting structure with a latch mechanism,according to at least one aspect of the present disclosure.

FIG. 73 illustrates an exploded view of FIG. 72, according to at leastone aspect of the present disclosure.

FIG. 74 illustrates a first alternative slider button for a latchmechanism, according to at least one aspect of the present disclosure.

FIG. 75 illustrates a second alternative slider button for a latchmechanism, according to at least one aspect of the present disclosure.

FIG. 76 illustrates a bottom view of a display, according to at leastone aspect of the present disclosure.

FIG. 77 illustrates a rear view of the display of FIG. 76, according toat least one aspect of the present disclosure.

FIG. 78 illustrates a side view of the display of FIG. 76, according toat least one aspect of the present disclosure.

FIG. 79 illustrates an isometric view of the display of FIG. 76,according to at least one aspect of the present disclosure.

FIG. 80 illustrates a partial internal view of a header module,according to at least one aspect of the present disclosure.

FIG. 81 illustrates a modular energy system, according to at least oneaspect of the present disclosure.

FIG. 82 illustrates a partial top view of a header module of the modularenergy system of FIG. 81, according to at least one aspect of thepresent disclosure.

FIG. 83 illustrates a partial isometric view of a header module of themodular energy system of FIG. 81, according to at least one aspect ofthe present disclosure.

FIG. 84 illustrates a side view of the modular energy system of FIG. 81,according to at least one aspect of the present disclosure.

FIG. 85 illustrates a side view of the header modular of the modularenergy system of FIG. 81, according to at least one aspect of thepresent disclosure.

FIG. 86 illustrates a partial isometric view of the header modular ofthe modular energy system of FIG. 81, according to at least one aspectof the present disclosure.

FIG. 87 illustrates a header module with a door covering a memorycompartment, according to at least one aspect of the present disclosure.

FIG. 88 illustrates illustrated the header module of FIG. 87 with thedoor removed, according to at least one aspect of the presentdisclosure.

FIG. 89 illustrates an alternative door for covering a memorycompartment, according to at least one aspect of the present disclosure.

FIG. 90 illustrates a side view of the door of FIG. 89, according to atleast one aspect of the present disclosure.

FIG. 91 illustrates a rear panel of a header module with apertures andPCB mounted connectors, according to at least one aspect of the presentdisclosure.

FIG. 92 illustrates a header module with crush ribs, according to atleast one aspect of the present disclosure.

FIG. 93 illustrates the header module of FIG. 92 with a crush ribcrushed under a PCB, according to at least one aspect of the presentdisclosure.

FIG. 94 illustrates an exploded view of an LCD subassembly, according toat least one aspect of the present disclosure.

FIG. 95 illustrates an LCD subassembly and a rear enclosure of a displayassembly, according to at least one aspect of the present disclosure.

FIG. 96 illustrates an assembled display assembly, according to at leastone aspect of the present disclosure.

FIG. 97 illustrates latches of an LCD subassembly coupled to a rearenclosure, according to at least one aspect of the present disclosure.

Corresponding reference characters indicate corresponding partsthroughout the several views. The exemplifications set out hereinillustrate various disclosed aspects, in one form, and suchexemplifications are not to be construed as limiting the scope thereofin any manner.

DESCRIPTION

Applicant of the present application owns the following U.S. patentapplications filed concurrently herewith, the disclosure of each ofwhich is herein incorporated by reference in its entirety:

-   U.S. Patent Application Docket No. END9314USNP2/210018-2, titled    BACKPLANE CONNECTOR ATTACHMENT MECHANISM FOR MODULAR ENERGY SYSTEM;-   U.S. Patent Application Docket No. END9314USNP3/210018-3, titled    BEZEL WITH LIGHT BLOCKING FEATURES FOR MODULAR ENERGY SYSTEM;-   U.S. Patent Application Docket No. END9314USNP4/210018-4, titled    HEADER FOR MODULAR ENERGY SYSTEM;-   U.S. Patent Application Docket No. END9315USNP1/210019, titled    SURGICAL PROCEDURALIZATION VIA MODULAR ENERGY SYSTEM;-   U.S. Patent Application Docket No. END9316USNP1/210020-1M, titled    METHOD FOR ENERGY DELIVERY FOR MODULAR ENERGY SYSTEM;-   U.S. Patent Application Docket No. END9316USNP2/210020-2, titled    MODULAR ENERGY SYSTEM WITH DUAL AMPLIFIERS AND TECHNIQUES FOR    UPDATING PARAMETERS THEREOF;-   U.S. Patent Application Docket No. END9316USNP3/210020-3, titled    MODULAR ENERGY SYSTEM WITH MULTI-ENERGY PORT SPLITTER FOR MULTIPLE    ENERGY DEVICES;-   U.S. Patent Application Docket No. END9317USNP1/210021-1M, titled    METHOD FOR INTELLIGENT INSTRUMENTS FOR MODULAR ENERGY SYSTEM;-   U.S. Patent Application Docket No. END9317USNP2/210021-2, titled    RADIO FREQUENCY IDENTIFICATION TOKEN FOR WIRELESS SURGICAL    INSTRUMENTS;-   U.S. Patent Application Docket No. END9317USNP3/210021-3, titled    INTELLIGENT DATA PORTS FOR MODULAR ENERGY SYSTEMS;-   U.S. Patent Application Docket No. END9318USNP1/210022-1M, titled    METHOD FOR SYSTEM ARCHITECTURE FOR MODULAR ENERGY SYSTEM;-   U.S. Patent Application Docket No. END9318USNP2/210022-2, titled    USER INTERFACE MITIGATION TECHNIQUES FOR MODULAR ENERGY SYSTEMS;-   U.S. Patent Application Docket No. END9318USNP3/210022-3, titled    ENERGY DELIVERY MITIGATIONS FOR MODULAR ENERGY SYSTEMS;-   U.S. Patent Application Docket No. END9318USNP4/210022-4, titled    ARCHITECTURE FOR MODULAR ENERGY SYSTEM; and-   U.S. Patent Application Docket No. END9318USNP5/210022-5, titled    MODULAR ENERGY SYSTEM WITH HARDWARE MITIGATED COMMUNICATION.

Applicant of the present application owns the following U.S. PatentApplications filed Sep. 5, 2019, the disclosure of each of which isherein incorporated by reference in its entirety:

-   U.S. patent application Ser. No. 16/562,144, titled METHOD FOR    CONTROLLING A MODULAR ENERGY SYSTEM USER INTERFACE, now U.S. Patent    Application Publication No. 2020/0078106;-   U.S. patent application Ser. No. 16/562,151, titled PASSIVE HEADER    MODULE FOR A MODULAR ENERGY SYSTEM, now U.S. Patent Application    Publication No. 2020/0078110;-   U.S. patent application Ser. No. 16/562,157, titled CONSOLIDATED    USER INTERFACE FOR MODULAR ENERGY SYSTEM, now U.S. Patent    Application Publication No. 2020/0081585;-   U.S. patent application Ser. No. 16/562,159, titled AUDIO TONE    CONSTRUCTION FOR AN ENERGY MODULE OF A MODULAR ENERGY SYSTEM, now    U.S. Patent Application Publication No. 2020/0314569;-   U.S. patent application Ser. No. 16/562,163, titled ADAPTABLY    CONNECTABLE AND REASSIGNABLE SYSTEM ACCESSORIES FOR MODULAR ENERGY    SYSTEM, now U.S. Patent Application Publication No. 2020/0078111;-   U.S. patent application Ser. No. 16/562,123, titled METHOD FOR    CONSTRUCTING AND USING A MODULAR SURGICAL ENERGY SYSTEM WITH    MULTIPLE DEVICES, now U.S. Patent Application Publication No.    2020/0100830;-   U.S. patent application Ser. No. 16/562,135, titled METHOD FOR    CONTROLLING AN ENERGY MODULE OUTPUT, now U.S. Patent Application    Publication No. 2020/0078076;-   U.S. patent application Ser. No. 16/562,180, titled ENERGY MODULE    FOR DRIVING MULTIPLE ENERGY MODALITIES, now U.S. Patent Application    Publication No. 2020/0078080;-   U.S. patent application Ser. No. 16/562,184, titled GROUNDING    ARRANGEMENT OF ENERGY MODULES, now U.S. Patent Application    Publication No. 2020/0078081;-   U.S. patent application Ser. No. 16/562,188, titled BACKPLANE    CONNECTOR DESIGN TO CONNECT STACKED ENERGY MODULES, now U.S. Patent    Application Publication No. 2020/0078116;-   U.S. patent application Ser. No. 16/562,195, titled ENERGY MODULE    FOR DRIVING MULTIPLE ENERGY MODALITIES THROUGH A PORT, now U.S.    Patent Application Publication No. 20200078117;-   U.S. patent application Ser. No. 16/562,202 titled SURGICAL    INSTRUMENT UTILIZING DRIVE SIGNAL TO POWER SECONDARY FUNCTION, now    U.S. Patent Application Publication No. 2020/0078082;-   U.S. patent application Ser. No. 16/562,142, titled METHOD FOR    ENERGY DISTRIBUTION IN A SURGICAL MODULAR ENERGY SYSTEM, now U.S.    Patent Application Publication No. 2020/0078070;-   U.S. patent application Ser. No. 16/562,169, titled SURGICAL MODULAR    ENERGY SYSTEM WITH A SEGMENTED BACKPLANE, now U.S. Patent    Application Publication No. 2020/0078112;-   U.S. patent application Ser. No. 16/562,185, titled SURGICAL MODULAR    ENERGY SYSTEM WITH FOOTER MODULE, now U.S. Patent Application    Publication No. 2020/0078115;-   U.S. patent application Ser. No. 16/562,203, titled POWER AND    COMMUNICATION MITIGATION ARRANGEMENT FOR MODULAR SURGICAL ENERGY    SYSTEM, now U.S. Patent Application Publication No. 2020/0078118;-   U.S. patent application Ser. No. 16/562,212, titled MODULAR SURGICAL    ENERGY SYSTEM WITH MODULE POSITIONAL AWARENESS SENSING WITH VOLTAGE    DETECTION, now U.S. Patent Application Publication No. 2020/0078119;-   U.S. patent application Ser. No. 16/562,234, titled MODULAR SURGICAL    ENERGY SYSTEM WITH MODULE POSITIONAL AWARENESS SENSING WITH TIME    COUNTER, now U.S. Patent Application Publication No. 2020/0305945;-   U.S. patent application Ser. No. 16/562,243, titled MODULAR SURGICAL    ENERGY SYSTEM WITH MODULE POSITIONAL AWARENESS WITH DIGITAL LOGIC,    now U.S. Patent Application Publication No. 2020/0078120;-   U.S. patent application Ser. No. 16/562,125, titled METHOD FOR    COMMUNICATING BETWEEN MODULES AND DEVICES IN A MODULAR SURGICAL    SYSTEM, now U.S. Patent Application Publication No. 2020/0100825;-   U.S. patent application Ser. No. 16/562,137, titled FLEXIBLE    HAND-SWITCH CIRCUIT, now U.S. Patent Application Publication No.    2020/0106220;-   U.S. patent application Ser. No. 16/562,143, titled FIRST AND SECOND    COMMUNICATION PROTOCOL ARRANGEMENT FOR DRIVING PRIMARY AND SECONDARY    DEVICES THROUGH A SINGLE PORT, now U.S. Patent Application    Publication No. 2020/0090808;-   U.S. patent application Ser. No. 16/562,148, titled FLEXIBLE NEUTRAL    ELECTRODE, now U.S. Patent Application Publication No. 2020/0078077;-   U.S. patent application Ser. No. 16/562,154, titled SMART RETURN PAD    SENSING THROUGH MODULATION OF NEAR FIELD COMMUNICATION AND CONTACT    QUALITY MONITORING SIGNALS, now U.S. Patent Application Publication    No. 2020/0078089;-   U.S. patent application Ser. No. 16/562,162, titled AUTOMATIC    ULTRASONIC ENERGY ACTIVATION CIRCUIT DESIGN FOR MODULAR SURGICAL    SYSTEMS, now U.S. Patent Application Publication No. 2020/0305924;-   U.S. patent application Ser. No. 16/562,167, titled COORDINATED    ENERGY OUTPUTS OF SEPARATE BUT CONNECTED MODULES, now U.S. Patent    Application Publication No. 2020/0078078;-   U.S. patent application Ser. No. 16/562,170, titled MANAGING    SIMULTANEOUS MONOPOLAR OUTPUTS USING DUTY CYCLE AND SYNCHRONIZATION,    now U.S. Patent Application Publication No. 2020/0078079;-   U.S. patent application Ser. No. 16/562,172, titled PORT PRESENCE    DETECTION SYSTEM FOR MODULAR ENERGY SYSTEM, now U.S. Patent    Application Publication No. 2020/0078113;-   U.S. patent application Ser. No. 16/562,175, titled INSTRUMENT    TRACKING ARRANGEMENT BASED ON REAL TIME CLOCK INFORMATION, now U.S.    Patent Application Publication No. 2020/0078071;-   U.S. patent application Ser. No. 16/562,177, titled REGIONAL    LOCATION TRACKING OF COMPONENTS OF A MODULAR ENERGY SYSTEM, now U.S.    Patent Application Publication No. 2020/0078114;-   U.S. Design Patent Application Serial No. 29/704,610, titled ENERGY    MODULE;-   U.S. Design Patent Application Serial No. 29/704,614, titled ENERGY    MODULE MONOPOLAR PORT WITH FOURTH SOCKET AMONG THREE OTHER SOCKETS;-   U.S. Design Patent Application Serial No. 29/704,616, titled    BACKPLANE CONNECTOR FOR ENERGY MODULE; and-   U.S. Design Patent Application Serial No. 29/704,617, titled ALERT    SCREEN FOR ENERGY MODULE.

Applicant of the present application owns the following U.S. PatentProvisional Applications filed Mar. 29, 2019, the disclosure of each ofwhich is herein incorporated by reference in its entirety:

-   U.S. Provisional Patent Application Ser. No. 62/826,584, titled    MODULAR SURGICAL PLATFORM ELECTRICAL ARCHITECTURE;-   U.S. Provisional Patent Application Ser. No. 62/826,587, titled    MODULAR ENERGY SYSTEM CONNECTIVITY;-   U.S. Provisional Patent Application Ser. No. 62/826,588, titled    MODULAR ENERGY SYSTEM INSTRUMENT COMMUNICATION TECHNIQUES; and-   U.S. Provisional Patent Application Ser. No. 62/826,592, titled    MODULAR ENERGY DELIVERY SYSTEM

Applicant of the present application owns the following U.S. PatentProvisional Application filed Sep. 7, 2018, the disclosure of each ofwhich is herein incorporated by reference in its entirety:

-   U.S. Provisional Patent Application Ser. No. 62/728,480, titled    MODULAR ENERGY SYSTEM AND USER INTERFACE.

Before explaining various aspects of surgical devices and generators indetail, it should be noted that the illustrative examples are notlimited in application or use to the details of construction andarrangement of parts illustrated in the accompanying drawings anddescription. The illustrative examples may be implemented orincorporated in other aspects, variations and modifications, and may bepracticed or carried out in various ways. Further, unless otherwiseindicated, the terms and expressions employed herein have been chosenfor the purpose of describing the illustrative examples for theconvenience of the reader and are not for the purpose of limitationthereof. Also, it will be appreciated that one or more of thefollowing-described aspects, expressions of aspects, and/or examples,can be combined with any one or more of the other following-describedaspects, expressions of aspects and/or examples.

Various aspects are directed to improved ultrasonic surgical devices,electrosurgical devices and generators for use therewith. Aspects of theultrasonic surgical devices can be configured for transecting and/orcoagulating tissue during surgical procedures, for example. Aspects ofthe electrosurgical devices can be configured for transecting,coagulating, scaling, welding and/or desiccating tissue during surgicalprocedures, for example.

Surgical System Hardware

Referring to FIG. 1, a computer-implemented interactive surgical system100 includes one or more surgical systems 102 and a cloud-based system(e.g., the cloud 104 that may include a remote server 113 coupled to astorage device 105). Each surgical system 102 includes at least onesurgical hub 106 in communication with the cloud 104 that may include aremote server 113. In one example, as illustrated in FIG. 1, thesurgical system 102 includes a visualization system 108, a roboticsystem 110, and a handheld intelligent surgical instrument 112, whichare configured to communicate with one another and/or the hub 106. Insome aspects, a surgical system 102 may include an M number of hubs 106,an N number of visualization systems 108, an O number of robotic systems110, and a P number of handheld intelligent surgical instruments 112,where M, N, O, and P are integers greater than or equal to one.

FIG. 2 depicts an example of a surgical system 102 being used to performa surgical procedure on a patient who is lying down on an operatingtable 114 in a surgical operating room 116. A robotic system 110 is usedin the surgical procedure as a part of the surgical system 102. Therobotic system 110 includes a surgeon's console 118, a patient side cart120 (surgical robot), and a surgical robotic hub 122. The patient sidecart 120 can manipulate at least one removably coupled surgical tool 117through a minimally invasive incision in the body of the patient whilethe surgeon views the surgical site through the surgeon's console 118.An image of the surgical site can be obtained by a medical imagingdevice 124, which can be manipulated by the patient side cart 120 toorient the imaging device 124. The robotic hub 122 can be used toprocess the images of the surgical site for subsequent display to thesurgeon through the surgeon's console 118.

Other types of robotic systems can be readily adapted for use with thesurgical system 102. Various examples of robotic systems and surgicaltools that are suitable for use with the present disclosure aredescribed in U.S. Provisional Patent Application Ser. No. 62/611,339,titled ROBOT ASSISTED SURGICAL PLATFORM, filed Dec. 28, 2017, thedisclosure of which is herein incorporated by reference in its entirety.

Various examples of cloud-based analytics that are performed by thecloud 104, and are suitable for use with the present disclosure, aredescribed in U.S. Provisional Patent Application Ser. No. 62/611,340,titled CLOUD-BASED MEDICAL ANALYTICS, filed Dec. 28, 2017, thedisclosure of which is herein incorporated by reference in its entirety.

In various aspects, the imaging device 124 includes at least one imagesensor and one or more optical components. Suitable image sensorsinclude, but are not limited to, Charge-Coupled Device (CCD) sensors andComplementary Metal-Oxide Semiconductor (CMOS) sensors.

The optical components of the imaging device 124 may include one or moreillumination sources and/or one or more lenses. The one or moreillumination sources may be directed to illuminate portions of thesurgical field. The one or more image sensors may receive lightreflected or refracted from the surgical field, including lightreflected or refracted from tissue and/or surgical instruments.

The one or more illumination sources may be configured to radiateelectromagnetic energy in the visible spectrum as well as the invisiblespectrum. The visible spectrum, sometimes referred to as the opticalspectrum or luminous spectrum, is that portion of the electromagneticspectrum that is visible to (i.e., can be detected by) the human eye andmay be referred to as visible light or simply light. A typical human eyewill respond to wavelengths in air that are from about 380 nm to about750 nm.

The invisible spectrum (i.e., the non-luminous spectrum) is that portionof the electromagnetic spectrum that lies below and above the visiblespectrum (i.e., wavelengths below about 380 nm and above about 750 nm).The invisible spectrum is not detectable by the human eye. Wavelengthsgreater than about 750 nm are longer than the red visible spectrum, andthey become invisible infrared (IR), microwave, and radioelectromagnetic radiation. Wavelengths less than about 380 nm areshorter than the violet spectrum, and they become invisible ultraviolet,x-ray, and gamma ray electromagnetic radiation.

In various aspects, the imaging device 124 is configured for use in aminimally invasive procedure. Examples of imaging devices suitable foruse with the present disclosure include, but not limited to, anarthroscope, angioscope, bronchoscope, choledochoscope, colonoscope,cytoscope, duodenoscope, enteroscope, esophagogastro-duodenoscope(gastroscope), endoscope, laryngoscope, nasopharyngo-neproscope,sigmoidoscope, thoracoscope, and ureteroscope.

In one aspect, the imaging device employs multi-spectrum monitoring todiscriminate topography and underlying structures. A multi-spectralimage is one that captures image data within specific wavelength rangesacross the electromagnetic spectrum. The wavelengths may be separated byfilters or by the use of instruments that are sensitive to particularwavelengths, including light from frequencies beyond the visible lightrange, e.g., IR and ultraviolet. Spectral imaging can allow extractionof additional information the human eye fails to capture with itsreceptors for red, green, and blue. The use of multi-spectral imaging isdescribed in greater detail under the heading “Advanced ImagingAcquisition Module” in U.S. Provisional Patent Application Ser. No.62/611,341, titled INTERACTIVE SURGICAL PLATFORM, filed Dec. 28, 2017,the disclosure of which is herein incorporated by reference in itsentirety. Multi-spectrum monitoring can be a useful tool in relocating asurgical field after a surgical task is completed to perform one or moreof the previously described tests on the treated tissue.

It is axiomatic that strict sterilization of the operating room andsurgical equipment is required during any surgery. The strict hygieneand sterilization conditions required in a “surgical theater,” i.e., anoperating or treatment room, necessitate the highest possible sterilityof all medical devices and equipment. Part of that sterilization processis the need to sterilize anything that comes in contact with the patientor penetrates the sterile field, including the imaging device 124 andits attachments and components. It will be appreciated that the sterilefield may be considered a specified area, such as within a tray or on asterile towel, that is considered free of microorganisms, or the sterilefield may be considered an area, immediately around a patient, who hasbeen prepared for a surgical procedure. The sterile field may includethe scrubbed team members, who are properly attired, and all furnitureand fixtures in the area.

In various aspects, the visualization system 108 includes one or moreimaging sensors, one or more image-processing units, one or more storagearrays, and one or more displays that are strategically arranged withrespect to the sterile field, as illustrated in FIG. 2. In one aspect,the visualization system 108 includes an interface for HL7, PACS, andEMR. Various components of the visualization system 108 are describedunder the heading “Advanced Imaging Acquisition Module” in U.S.Provisional Patent Application Ser. No. 62/611,341, titled INTERACTIVESURGICAL PLATFORM, filed Dec. 28, 2017, the disclosure of which isherein incorporated by reference in its entirety.

As illustrated in FIG. 2, a primary display 119 is positioned in thesterile field to be visible to an operator at the operating table 114.In addition, a visualization tower 111 is positioned outside the sterilefield. The visualization tower 111 includes a first non-sterile display107 and a second non-sterile display 109, which face away from eachother. The visualization system 108, guided by the hub 106, isconfigured to utilize the displays 107, 109, and 119 to coordinateinformation flow to operators inside and outside the sterile field. Forexample, the hub 106 may cause the visualization system 108 to display asnapshot of a surgical site, as recorded by an imaging device 124, on anon-sterile display 107 or 109, while maintaining a live feed of thesurgical site on the primary display 119. The snapshot on thenon-sterile display 107 or 109 can permit a non-sterile operator toperform a diagnostic step relevant to the surgical procedure, forexample.

In one aspect, the hub 106 is also configured to route a diagnosticinput or feedback entered by a non-sterile operator at the visualizationtower 111 to the primary display 119 within the sterile field, where itcan be viewed by a sterile operator at the operating table. In oneexample, the input can be in the form of a modification to the snapshotdisplayed on the non-sterile display 107 or 109, which can be routed tothe primary display 119 by the hub 106.

Referring to FIG. 2, a surgical instrument 112 is being used in thesurgical procedure as part of the surgical system 102. The hub 106 isalso configured to coordinate information flow to a display of thesurgical instrument 112. For example, in U.S. Provisional PatentApplication Ser. No. 62/611,341, titled INTERACTIVE SURGICAL PLATFORM,filed Dec. 28, 2017, the disclosure of which is herein incorporated byreference in its entirety. A diagnostic input or feedback entered by anon-sterile operator at the visualization tower 111 can be routed by thehub 106 to the surgical instrument display 115 within the sterile field,where it can be viewed by the operator of the surgical instrument 112.Example surgical instruments that are suitable for use with the surgicalsystem 102 are described under the heading SURGICAL INSTRUMENT HARDWAREand in U.S. Provisional Patent Application Ser. No. 62/611,341, titledINTERACTIVE SURGICAL PLATFORM, filed Dec. 28, 2017, the disclosure ofwhich is herein incorporated by reference in its entirety, for example.

Referring now to FIG. 3, a hub 106 is depicted in communication with avisualization system 108, a robotic system 110, and a handheldintelligent surgical instrument 112. In some aspects, the visualizationsystem 108 may be a separable piece of equipment. In alternativeaspects, the visualization system 108 could be contained within the hub106 as a functional module. The hub 106 includes a hub display 135, animaging module 138, a generator module 140, a communication module 130,a processor module 132, a storage array 134, and an operating roommapping module 133. In certain aspects, as illustrated in FIG. 3, thehub 106 further includes a smoke evacuation module 126, asuction/irrigation module 128, and/or an insufflation module 129. Incertain aspects, any of the modules in the hub 106 may be combined witheach other into a single module.

During a surgical procedure, energy application to tissue, for sealingand/or cutting, is generally associated with smoke evacuation, suctionof excess fluid, and/or irrigation of the tissue. Fluid, power, and/ordata lines from different sources are often entangled during thesurgical procedure. Valuable time can be lost addressing this issueduring a surgical procedure. Detangling the lines may necessitatedisconnecting the lines from their respective modules, which may requireresetting the modules. The hub modular enclosure 136 offers a unifiedenvironment for managing the power, data, and fluid lines, which reducesthe frequency of entanglement between such lines.

Aspects of the present disclosure present a surgical hub for use in asurgical procedure that involves energy application to tissue at asurgical site. The surgical hub includes a hub enclosure and a combogenerator module slidably receivable in a docking station of the hubenclosure. The docking station includes data and power contacts. Thecombo generator module includes one or more of an ultrasonic energygenerator component, a bipolar RF energy generator component, and amonopolar RF energy generator component that are housed in a singleunit. In one aspect, the combo generator module also includes a smokeevacuation component, at least one energy delivery cable for connectingthe combo generator module to a surgical instrument, at least one smokeevacuation component configured to evacuate smoke, fluid, and/orparticulates generated by the application of therapeutic energy to thetissue, and a fluid line extending from the remote surgical site to thesmoke evacuation component.

In one aspect, the fluid line is a first fluid line and a second fluidline extends from the remote surgical site to a suction and irrigationmodule slidably received in the hub enclosure. In one aspect, the hubenclosure comprises a fluid interface.

Certain surgical procedures may require the application of more than oneenergy type to the tissue. One energy type may be more beneficial forcutting the tissue, while another different energy type may be morebeneficial for sealing the tissue. For example, a bipolar generator canbe used to seal the tissue while an ultrasonic generator can be used tocut the sealed tissue. Aspects of the present disclosure present asolution where a hub modular enclosure 136 is configured to accommodatedifferent generators, and facilitate an interactive communicationtherebetween. One of the advantages of the hub modular enclosure 136 isenabling the quick removal and/or replacement of various modules.

Aspects of the present disclosure present a modular surgical enclosurefor use in a surgical procedure that involves energy application totissue. The modular surgical enclosure includes a first energy-generatormodule, configured to generate a first energy for application to thetissue, and a first docking station comprising a first docking port thatincludes first data and power contacts. In one aspect, the firstenergy-generator module is slidably movable into an electricalengagement with the power and data contacts and wherein the firstenergy-generator module is slidably movable out of the electricalengagement with the first power and data contacts. In an alternativeaspect, the first energy-generator module is stackably movable into anelectrical engagement with the power and data contacts and wherein thefirst energy-generator module is stackably movable out of the electricalengagement with the first power and data contacts.

Further to the above, the modular surgical enclosure also includes asecond energy-generator module configured to generate a second energy,either the same or different than the first energy, for application tothe tissue, and a second docking station comprising a second dockingport that includes second data and power contacts. In one aspect, thesecond energy-generator module is slidably movable into an electricalengagement with the power and data contacts, and wherein the secondenergy-generator module is slidably movable out of the electricalengagement with the second power and data contacts. In an alternativeaspect, the second energy-generator module is stackably movable into anelectrical engagement with the power and data contacts, and wherein thesecond energy-generator module is stackably movable out of theelectrical engagement with the second power and data contacts.

In addition, the modular surgical enclosure also includes acommunication bus between the first docking port and the second dockingport, configured to facilitate communication between the firstenergy-generator module and the second energy-generator module.

Referring to FIG. 3, aspects of the present disclosure are presented fora hub modular enclosure 136 that allows the modular integration of agenerator module 140, a smoke evacuation module 126, asuction/irrigation module 128, and an insufflation module 129. The hubmodular enclosure 136 further facilitates interactive communicationbetween the modules 140, 126, 128, 129. The generator module 140 can bea generator module with integrated monopolar, bipolar, and ultrasoniccomponents supported in a single housing unit slidably insertable intothe hub modular enclosure 136. The generator module 140 can beconfigured to connect to a monopolar device 142, a bipolar device 144,and an ultrasonic device 148. Alternatively, the generator module 140may comprise a series of monopolar, bipolar, and/or ultrasonic generatormodules that interact through the hub modular enclosure 136. The hubmodular enclosure 136 can be configured to facilitate the insertion ofmultiple generators and interactive communication between the generatorsdocked into the hub modular enclosure 136 so that the generators wouldact as a single generator.

In one aspect, the hub modular enclosure 136 comprises a modular powerand communication backplane 149 with external and wireless communicationheaders to enable the removable attachment of the modules 140, 126, 128,129 and interactive communication therebetween.

Generator Hardware

As used throughout this description, the term “wireless” and itsderivatives may be used to describe circuits, devices, systems, methods,techniques, communications channels, etc., that may communicate datathrough the use of modulated electromagnetic radiation through anon-solid medium. The term does not imply that the associated devices donot contain any wires, although in some aspects they might not. Thecommunication module may implement any of a number of wireless or wiredcommunication standards or protocols, including but not limited to Wi-Fi(IEEE 802.11 family), WiMAX (IEEE 802.16 family), IEEE 802.20, long termevolution (LTE), Ev-DO, HSPA+, HSDPA+, HSUPA+, EDGE, GSM, GPRS, CDMA,TDMA, DECT, Bluetooth, Ethernet derivatives thereof, as well as anyother wireless and wired protocols that are designated as 3G, 4G, 5G,and beyond. The computing module may include a plurality ofcommunication modules. For instance, a first communication module may bededicated to shorter range wireless communications such as Wi-Fi andBluetooth and a second communication module may be dedicated to longerrange wireless communications such as GPS, EDGE, GPRS, CDMA, WiMAX, LTE,Ev-DO, and others.

As used herein a processor or processing unit is an electronic circuitwhich performs operations on some external data source, usually memoryor some other data stream. The term is used herein to refer to thecentral processor (central processing unit) in a system or computersystems (especially systems on a chip (SoCs)) that combine a number ofspecialized “processors.”

As used herein, a system on a chip or system on chip (SoC or SOC) is anintegrated circuit (also known as an “IC” or “chip”) that integrates allcomponents of a computer or other electronic systems. It may containdigital, analog, mixed-signal, and often radio-frequency functions—allon a single substrate. A SoC integrates a microcontroller (ormicroprocessor) with advanced peripherals like graphics processing unit(GPU), Wi-Fi module, or coprocessor. A SoC may or may not containbuilt-in memory.

As used herein, a microcontroller or controller is a system thatintegrates a microprocessor with peripheral circuits and memory. Amicrocontroller (or MCU for microcontroller unit) may be implemented asa small computer on a single integrated circuit. It may be similar to aSoC; a SoC may include a microcontroller as one of its components. Amicrocontroller may contain one or more core processing units (CPUs)along with memory and programmable input/output peripherals. Programmemory in the form of Ferroelectric RAM, NOR flash or OTP ROM is alsooften included on chip, as well as a small amount of RAM.Microcontrollers may be employed for embedded applications, in contrastto the microprocessors used in personal computers or other generalpurpose applications consisting of various discrete chips.

As used herein, the term controller or microcontroller may be astand-alone IC or chip device that interfaces with a peripheral device.This may be a link between two parts of a computer or a controller on anexternal device that manages the operation of (and connection with) thatdevice.

Any of the processors or microcontrollers described herein, may beimplemented by any single core or multicore processor such as thoseknown under the trade name ARM Cortex by Texas Instruments. In oneaspect, the processor may be an LM4F230H5QR ARM Cortex-M4F ProcessorCore, available from Texas Instruments, for example, comprising on-chipmemory of 256 KB single-cycle flash memory, or other non-volatilememory, up to 40 MHz, a prefetch buffer to improve performance above 40MHz, a 32 KB single-cycle serial random access memory (SRAM), internalread-only memory (ROM) loaded with StellarisWare® software, 2 KBelectrically erasable programmable read-only memory (EEPROM), one ormore pulse width modulation (PWM) modules, one or more quadratureencoder inputs (QEI) analog, one or more 12-bit Analog-to-DigitalConverters (ADC) with 12 analog input channels, details of which areavailable for the product datasheet.

In one aspect, the processor may comprise a safety controller comprisingtwo controller-based families such as TMS570 and RM4x known under thetrade name Hercules ARM Cortex R4, also by Texas Instruments. The safetycontroller may be configured specifically for IEC 61508 and ISO 26262safety critical applications, among others, to provide advancedintegrated safety features while delivering scalable performance,connectivity, and memory options.

Modular devices include the modules (as described in connection withFIG. 3, for example) that are receivable within a surgical hub and thesurgical devices or instruments that can be connected to the variousmodules in order to connect or pair with the corresponding surgical hub.The modular devices include, for example, intelligent surgicalinstruments, medical imaging devices, suction/irrigation devices, smokeevacuators, energy generators, ventilators, insufflators, and displays.The modular devices described herein can be controlled by controlalgorithms. The control algorithms can be executed on the modular deviceitself, on the surgical hub to which the particular modular device ispaired, or on both the modular device and the surgical hub (e.g., via adistributed computing architecture). In some exemplifications, themodular devices' control algorithms control the devices based on datasensed by the modular device itself (i.e., by sensors in, on, orconnected to the modular device). This data can be related to thepatient being operated on (e.g., tissue properties or insufflationpressure) or the modular device itself (e.g., the rate at which a knifeis being advanced, motor current, or energy levels). For example, acontrol algorithm for a surgical stapling and cutting instrument cancontrol the rate at which the instrument's motor drives its knifethrough tissue according to resistance encountered by the knife as itadvances.

FIG. 4 illustrates one form of a surgical system 2200 comprising amodular energy system 2000 and various surgical instruments 2204, 2206,2208 usable therewith, where the surgical instrument 2204 is anultrasonic surgical instrument, the surgical instrument 2206 is an RFelectrosurgical instrument, and the multifunction surgical instrument2208 is a combination ultrasonic/RF electrosurgical instrument. Themodular energy system 2000 is configurable for use with a variety ofsurgical instruments. According to various forms, the modular energysystem 2000 may be configurable for use with different surgicalinstruments of different types including, for example, ultrasonicsurgical instruments 2204, RF electrosurgical instruments 2206, andmultifunction surgical instruments 2208 that integrate RF and ultrasonicenergies delivered individually or simultaneously from the modularenergy system 2000. Although in the form of FIG. 4 the modular energysystem 2000 is shown separate from the surgical instruments 2204, 2206,2208 in one form, the modular energy system 2000 may be formedintegrally with any of the surgical instruments 2204, 2206, 2208 to forma unitary surgical system. The modular energy system 2000 may beconfigured for wired or wireless communication.

The modular energy system 2000 is configured to drive multiple surgicalinstruments 2204, 2206, 2208. The first surgical instrument is anultrasonic surgical instrument 2204 and comprises a handpiece 2205 (HP),an ultrasonic transducer 2220, a shaft 2226, and an end effector 2222.The end effector 2222 comprises an ultrasonic blade 2228 acousticallycoupled to the ultrasonic transducer 2220 and a clamp arm 2240. Thehandpiece 2205 comprises a trigger 2243 to operate the clamp arm 2240and a combination of the toggle buttons 2234 a, 2234 b, 2234 c toenergize and drive the ultrasonic blade 2228 or other function. Thetoggle buttons 2234 a, 2234 b, 2234 c can be configured to energize theultrasonic transducer 2220 with the modular energy system 2000.

The modular energy system 2000 also is configured to drive a secondsurgical instrument 2206. The second surgical instrument 2206 is an RFelectrosurgical instrument and comprises a handpiece 2207 (HP), a shaft2227, and an end effector 2224. The end effector 2224 compriseselectrodes in clamp arms 2242 a, 2242 b and return through an electricalconductor portion of the shaft 2227. The electrodes are coupled to andenergized by a bipolar energy source within the modular energy system2000. The handpiece 2207 comprises a trigger 2245 to operate the clamparms 2242 a, 2242 b and an energy button 2235 to actuate an energyswitch to energize the electrodes in the end effector 2224.

The modular energy system 2000 also is configured to drive amultifunction surgical instrument 2208. The multifunction surgicalinstrument 2208 comprises a handpiece 2209 (HP), a shaft 2229, and anend effector 2225. The end effector 2225 comprises an ultrasonic blade2249 and a clamp arm 2246. The ultrasonic blade 2249 is acousticallycoupled to the ultrasonic transducer 2220. The ultrasonic transducer2220 may be separable from or integral to the handpiece 2209. Thehandpiece 2209 comprises a trigger 2247 to operate the clamp arm 2246and a combination of the toggle buttons 2237 a, 2237 b, 2237 c toenergize and drive the ultrasonic blade 2249 or other function. Thetoggle buttons 2237 a, 2237 b, 2237 c can be configured to energize theultrasonic transducer 2220 with the modular energy system 2000 andenergize the ultrasonic blade 2249 with a bipolar energy source alsocontained within the modular energy system 2000.

The modular energy system 2000 is configurable for use with a variety ofsurgical instruments. According to various forms, the modular energysystem 2000 may be configurable for use with different surgicalinstruments of different types including, for example, the ultrasonicsurgical instrument 2204, the RF electrosurgical instrument 2206, andthe multifunction surgical instrument 2208 that integrates RF andultrasonic energies delivered individually or simultaneously from themodular energy system 2000. Although in the form of FIG. 4 the modularenergy system 2000 is shown separate from the surgical instruments 2204,2206, 2208, in another form the modular energy system 2000 may be formedintegrally with any one of the surgical instruments 2204, 2206, 2208 toform a unitary surgical system. Further aspects of generators fordigitally generating electrical signal waveforms and surgicalinstruments are described in US patent publication US-2017-0086914-A1,which is herein incorporated by reference in its entirety.

Situational Awareness

Although an “intelligent” device including control algorithms thatrespond to sensed data can be an improvement over a “dumb” device thatoperates without accounting for sensed data, some sensed data can beincomplete or inconclusive when considered in isolation, i.e., withoutthe context of the type of surgical procedure being performed or thetype of tissue that is being operated on. Without knowing the proceduralcontext (e.g., knowing the type of tissue being operated on or the typeof procedure being performed), the control algorithm may control themodular device incorrectly or sub optimally given the particularcontext-free sensed data. For example, the optimal manner for a controlalgorithm to control a surgical instrument in response to a particularsensed parameter can vary according to the particular tissue type beingoperated on. This is due to the fact that different tissue types havedifferent properties (e.g., resistance to tearing) and thus responddifferently to actions taken by surgical instruments. Therefore, it maybe desirable for a surgical instrument to take different actions evenwhen the same measurement for a particular parameter is sensed. As onespecific example, the optimal manner in which to control a surgicalstapling and cutting instrument in response to the instrument sensing anunexpectedly high force to close its end effector will vary dependingupon whether the tissue type is susceptible or resistant to tearing. Fortissues that are susceptible to tearing, such as lung tissue, theinstrument's control algorithm would optimally ramp down the motor inresponse to an unexpectedly high force to close to avoid tearing thetissue. For tissues that are resistant to tearing, such as stomachtissue, the instrument's control algorithm would optimally ramp up themotor in response to an unexpectedly high force to close to ensure thatthe end effector is clamped properly on the tissue. Without knowingwhether lung or stomach tissue has been clamped, the control algorithmmay make a suboptimal decision.

One solution utilizes a surgical hub including a system that isconfigured to derive information about the surgical procedure beingperformed based on data received from various data sources and thencontrol the paired modular devices accordingly. In other words, thesurgical hub is configured to infer information about the surgicalprocedure from received data and then control the modular devices pairedto the surgical hub based upon the inferred context of the surgicalprocedure. FIG. 5 illustrates a diagram of a situationally awaresurgical system 2300, in accordance with at least one aspect of thepresent disclosure. In some exemplifications, the data sources 2326include, for example, the modular devices 2302 (which can includesensors configured to detect parameters associated with the patientand/or the modular device itself), databases 2322 (e.g., an EMR databasecontaining patient records), and patient monitoring devices 2324 (e.g.,a blood pressure (BP) monitor and an electrocardiography (EKG) monitor).The surgical hub 2304 can be configured to derive the contextualinformation pertaining to the surgical procedure from the data basedupon, for example, the particular combination(s) of received data or theparticular order in which the data is received from the data sources2326. The contextual information inferred from the received data caninclude, for example, the type of surgical procedure being performed,the particular step of the surgical procedure that the surgeon isperforming, the type of tissue being operated on, or the body cavitythat is the subject of the procedure. This ability by some aspects ofthe surgical hub 2304 to derive or infer information related to thesurgical procedure from received data can be referred to as “situationalawareness.” In one exemplification, the surgical hub 2304 canincorporate a situational awareness system, which is the hardware and/orprogramming associated with the surgical hub 2304 that derivescontextual information pertaining to the surgical procedure from thereceived data.

The situational awareness system of the surgical hub 2304 can beconfigured to derive the contextual information from the data receivedfrom the data sources 2326 in a variety of different ways. In oneexemplification, the situational awareness system includes a patternrecognition system, or machine learning system (e.g., an artificialneural network), that has been trained on training data to correlatevarious inputs (e.g., data from databases 2322, patient monitoringdevices 2324, and/or modular devices 2302) to corresponding contextualinformation regarding a surgical procedure. In other words, a machinelearning system can be trained to accurately derive contextualinformation regarding a surgical procedure from the provided inputs. Inanother exemplification, the situational awareness system can include alookup table storing pre-characterized contextual information regardinga surgical procedure in association with one or more inputs (or rangesof inputs) corresponding to the contextual information. In response to aquery with one or more inputs, the lookup table can return thecorresponding contextual information for the situational awarenesssystem for controlling the modular devices 2302. In one exemplification,the contextual information received by the situational awareness systemof the surgical hub 2304 is associated with a particular controladjustment or set of control adjustments for one or more modular devices2302. In another exemplification, the situational awareness systemincludes a further machine learning system, lookup table, or other suchsystem, which generates or retrieves one or more control adjustments forone or more modular devices 2302 when provided the contextualinformation as input.

A surgical hub 2304 incorporating a situational awareness systemprovides a number of benefits for the surgical system 2300. One benefitincludes improving the interpretation of sensed and collected data,which would in turn improve the processing accuracy and/or the usage ofthe data during the course of a surgical procedure. To return to aprevious example, a situationally aware surgical hub 2304 coulddetermine what type of tissue was being operated on; therefore, when anunexpectedly high force to close the surgical instrument's end effectoris detected, the situationally aware surgical hub 2304 could correctlyramp up or ramp down the motor of the surgical instrument for the typeof tissue.

As another example, the type of tissue being operated can affect theadjustments that are made to the compression rate and load thresholds ofa surgical stapling and cutting instrument for a particular tissue gapmeasurement. A situationally aware surgical hub 2304 could infer whethera surgical procedure being performed is a thoracic or an abdominalprocedure, allowing the surgical hub 2304 to determine whether thetissue clamped by an end effector of the surgical stapling and cuttinginstrument is lung (for a thoracic procedure) or stomach (for anabdominal procedure) tissue. The surgical hub 2304 could then adjust thecompression rate and load thresholds of the surgical stapling andcutting instrument appropriately for the type of tissue.

As yet another example, the type of body cavity being operated in duringan insufflation procedure can affect the function of a smoke evacuator.A situationally aware surgical hub 2304 could determine whether thesurgical site is under pressure (by determining that the surgicalprocedure is utilizing insufflation) and determine the procedure type.As a procedure type is generally performed in a specific body cavity,the surgical hub 2304 could then control the motor rate of the smokeevacuator appropriately for the body cavity being operated in. Thus, asituationally aware surgical hub 2304 could provide a consistent amountof smoke evacuation for both thoracic and abdominal procedures.

As yet another example, the type of procedure being performed can affectthe optimal energy level at which an ultrasonic surgical instrument orradio frequency (RF) electrosurgical instrument operates. Arthroscopicprocedures, for example, require higher energy levels because the endeffector of the ultrasonic surgical instrument or RF electrosurgicalinstrument is immersed in fluid. A situationally aware surgical hub 2304could determine whether the surgical procedure is an arthroscopicprocedure. The surgical hub 2304 could then adjust the RF power level orthe ultrasonic amplitude of the generator (i.e., “energy level”) tocompensate for the fluid filled environment. Relatedly, the type oftissue being operated on can affect the optimal energy level for anultrasonic surgical instrument or RF electrosurgical instrument tooperate at. A situationally aware surgical hub 2304 could determine whattype of surgical procedure is being performed and then customize theenergy level for the ultrasonic surgical instrument or RFelectrosurgical instrument, respectively, according to the expectedtissue profile for the surgical procedure. Furthermore, a situationallyaware surgical hub 2304 can be configured to adjust the energy level forthe ultrasonic surgical instrument or RF electrosurgical instrumentthroughout the course of a surgical procedure, rather than just on aprocedure-by-procedure basis. A situationally aware surgical hub 2304could determine what step of the surgical procedure is being performedor will subsequently be performed and then update the control algorithmsfor the generator and/or ultrasonic surgical instrument or RFelectrosurgical instrument to set the energy level at a valueappropriate for the expected tissue type according to the surgicalprocedure step.

As yet another example, data can be drawn from additional data sources2326 to improve the conclusions that the surgical hub 2304 draws fromone data source 2326. A situationally aware surgical hub 2304 couldaugment data that it receives from the modular devices 2302 withcontextual information that it has built up regarding the surgicalprocedure from other data sources 2326. For example, a situationallyaware surgical hub 2304 can be configured to determine whetherhemostasis has occurred (i.e., whether bleeding at a surgical site hasstopped) according to video or image data received from a medicalimaging device. However, in some cases the video or image data can beinconclusive. Therefore, in one exemplification, the surgical hub 2304can be further configured to compare a physiologic measurement (e.g.,blood pressure sensed by a BP monitor communicably connected to thesurgical hub 2304) with the visual or image data of hemostasis (e.g.,from a medical imaging device 124 (FIG. 2) communicably coupled to thesurgical hub 2304) to make a determination on the integrity of thestaple line or tissue weld. In other words, the situational awarenesssystem of the surgical hub 2304 can consider the physiologicalmeasurement data to provide additional context in analyzing thevisualization data. The additional context can be useful when thevisualization data may be inconclusive or incomplete on its own.

Another benefit includes proactively and automatically controlling thepaired modular devices 2302 according to the particular step of thesurgical procedure that is being performed to reduce the number of timesthat medical personnel are required to interact with or control thesurgical system 2300 during the course of a surgical procedure. Forexample, a situationally aware surgical hub 2304 could proactivelyactivate the generator to which an RF electrosurgical instrument isconnected if it determines that a subsequent step of the procedurerequires the use of the instrument. Proactively activating the energysource allows the instrument to be ready for use a soon as the precedingstep of the procedure is completed.

As another example, a situationally aware surgical hub 2304 coulddetermine whether the current or subsequent step of the surgicalprocedure requires a different view or degree of magnification on thedisplay according to the feature(s) at the surgical site that thesurgeon is expected to need to view. The surgical hub 2304 could thenproactively change the displayed view (supplied by, e.g., a medicalimaging device for the visualization system 108) accordingly so that thedisplay automatically adjusts throughout the surgical procedure.

As yet another example, a situationally aware surgical hub 2304 coulddetermine which step of the surgical procedure is being performed orwill subsequently be performed and whether particular data orcomparisons between data will be required for that step of the surgicalprocedure. The surgical hub 2304 can be configured to automatically callup data screens based upon the step of the surgical procedure beingperformed, without waiting for the surgeon to ask for the particularinformation.

Another benefit includes checking for errors during the setup of thesurgical procedure or during the course of the surgical procedure. Forexample, a situationally aware surgical hub 2304 could determine whetherthe operating theater is setup properly or optimally for the surgicalprocedure to be performed. The surgical hub 2304 can be configured todetermine the type of surgical procedure being performed, retrieve thecorresponding checklists, product location, or setup needs (e.g., from amemory), and then compare the current operating theater layout to thestandard layout for the type of surgical procedure that the surgical hub2304 determines is being performed. In one exemplification, the surgicalhub 2304 can be configured to compare the list of items for theprocedure (scanned by a scanner, for example) and/or a list of devicespaired with the surgical hub 2304 to a recommended or anticipatedmanifest of items and/or devices for the given surgical procedure. Ifthere are any discontinuities between the lists, the surgical hub 2304can be configured to provide an alert indicating that a particularmodular device 2302, patient monitoring device 2324, and/or othersurgical item is missing. In one exemplification, the surgical hub 2304can be configured to determine the relative distance or position of themodular devices 2302 and patient monitoring devices 2324 via proximitysensors, for example. The surgical hub 2304 can compare the relativepositions of the devices to a recommended or anticipated layout for theparticular surgical procedure. If there are any discontinuities betweenthe layouts, the surgical hub 2304 can be configured to provide an alertindicating that the current layout for the surgical procedure deviatesfrom the recommended layout.

As another example, a situationally aware surgical hub 2304 coulddetermine whether the surgeon (or other medical personnel) was making anerror or otherwise deviating from the expected course of action duringthe course of a surgical procedure. For example, the surgical hub 2304can be configured to determine the type of surgical procedure beingperformed, retrieve the corresponding list of steps or order ofequipment usage (e.g., from a memory), and then compare the steps beingperformed or the equipment being used during the course of the surgicalprocedure to the expected steps or equipment for the type of surgicalprocedure that the surgical hub 2304 determined is being performed. Inone exemplification, the surgical hub 2304 can be configured to providean alert indicating that an unexpected action is being performed or anunexpected device is being utilized at the particular step in thesurgical procedure.

Overall, the situational awareness system for the surgical hub 2304improves surgical procedure outcomes by adjusting the surgicalinstruments (and other modular devices 2302) for the particular contextof each surgical procedure (such as adjusting to different tissue types)and validating actions during a surgical procedure. The situationalawareness system also improves surgeons' efficiency in performingsurgical procedures by automatically suggesting next steps, providingdata, and adjusting displays and other modular devices 2302 in thesurgical theater according to the specific context of the procedure.

Modular Energy System

ORs everywhere in the world are a tangled web of cords, devices, andpeople due to the amount of equipment required to perform surgicalprocedures. Surgical capital equipment tends to be a major contributorto this issue because most surgical capital equipment performs a single,specialized task. Due to their specialized nature and the surgeons'needs to utilize multiple different types of devices during the courseof a single surgical procedure, an OR may be forced to be stocked withtwo or even more pieces of surgical capital equipment, such as energygenerators. Each of these pieces of surgical capital equipment may needto be individually plugged into a power source and may be connected toone or more other devices that are being passed between OR personnel,creating a tangle of cords that have to be navigated. Another issuefaced in modern ORs is that each of these specialized pieces of surgicalcapital equipment has its own user interface and needs to beindependently controlled from the other pieces of equipment within theOR. This creates complexity in properly controlling multiple differentdevices in connection with each other and forces users to be trained onand memorize different types of user interfaces (which may furtherchange based upon the task or surgical procedure being performed, inaddition to changing between each piece of capital equipment). Thiscumbersome, complex process can necessitate the need for even moreindividuals to be present within the OR and can create danger ifmultiple devices are not properly controlled in tandem with each other.Therefore, consolidating surgical capital equipment technology intosingular systems that are able to flexibly address surgeons' needs toreduce the footprint of surgical capital equipment within ORs wouldsimplify the user experience, reduce the amount of clutter in ORs, andprevent difficulties and dangers associated with simultaneouslycontrolling multiple pieces of capital equipment. Further, making suchsystems expandable or customizable would allow for new technology to beconveniently incorporated into existing surgical systems, obviating theneed to replace entire surgical systems or for OR personnel to learn newuser interfaces or equipment controls with each new technology.

As described in FIGS. 1-3, a surgical hub 106 can be configured tointerchangeably receive a variety of modules, which can in turninterface with surgical devices (e.g., a surgical instrument or a smokeevacuator) or provide various other functions (e.g., communications). Inone aspect, a surgical hub 106 can be embodied as a modular energysystem 2000, which is illustrated in connection with FIGS. 6-12. Themodular energy system 2000 can include a variety of different modules2001 that are connectable together in a stacked configuration. In oneaspect, the modules 2001 can be both physically and communicably coupledtogether when stacked or otherwise connected together into a singularassembly. Further, the modules 2001 can be interchangeably connectabletogether in different combinations or arrangements. In one aspect, eachof the modules 2001 can include a consistent or universal array ofconnectors disposed along their upper and lower surfaces, therebyallowing any module 2001 to be connected to another module 2001 in anyarrangement (except that, in some aspects, a particular module type,such as the header module 2002, can be configured to serve as theuppermost module within the stack, for example). In an alternativeaspect, the modular energy system 2000 can include a housing that isconfigured to receive and retain the modules 2001, as is shown in FIG.3. The modular energy system 2000 can also include a variety ofdifferent components or accessories that are also connectable to orotherwise associatable with the modules 2001. In another aspect, themodular energy system 2000 can be embodied as a generator module 140(FIG. 3) of a surgical hub 106. In yet another aspect, the modularenergy system 2000 can be a distinct system from a surgical hub 106. Insuch aspects, the modular energy system 2000 can be communicablycouplable to a surgical hub 206 for transmitting and/or receiving datatherebetween.

The modular energy system 2000 can be assembled from a variety ofdifferent modules 2001, some examples of which are illustrated in FIG.6. Each of the different types of modules 2001 can provide differentfunctionality, thereby allowing the modular energy system 2000 to beassembled into different configurations to customize the functions andcapabilities of the modular energy system 2000 by customizing themodules 2001 that are included in each modular energy system 2000. Themodules 2001 of the modular energy system 2000 can include, for example,a header module 2002 (which can include a display screen 2006), anenergy module 2004, a technology module 2040, and a visualization module2042. In the depicted aspect, the header module 2002 is configured toserve as the top or uppermost module within the modular energy systemstack and can thus lack connectors along its top surface. In anotheraspect, the header module 2002 can be configured to be positioned at thebottom or the lowermost module within the modular energy system stackand can thus lack connectors along its bottom surface. In yet anotheraspect, the header module 2002 can be configured to be positioned at anintermediate position within the modular energy system stack and canthus include connectors along both its bottom and top surfaces. Theheader module 2002 can be configured to control the system-wide settingsof each module 2001 and component connected thereto through physicalcontrols 2011 thereon and/or a graphical user interface (GUI) 2008rendered on the display screen 2006. Such settings could include theactivation of the modular energy system 2000, the volume of alerts, thefootswitch settings, the settings icons, the appearance or configurationof the user interface, the surgeon profile logged into the modularenergy system 2000, and/or the type of surgical procedure beingperformed. The header module 2002 can also be configured to providecommunications, processing, and/or power for the modules 2001 that areconnected to the header module 2002. The energy module 2004, which canalso be referred to as a generator module 140 (FIG. 3), can beconfigured to generate one or multiple energy modalities for drivingelectrosurgical and/or ultrasonic surgical instruments connectedthereto. The technology module 2040 can be configured to provideadditional or expanded control algorithms (e.g., electrosurgical orultrasonic control algorithms for controlling the energy output of theenergy module 2004). The visualization module 2042 can be configured tointerface with visualization devices (i.e., scopes) and accordinglyprovide increased visualization capabilities.

The modular energy system 2000 can further include a variety ofaccessories 2029 that are connectable to the modules 2001 forcontrolling the functions thereof or that are otherwise configured towork on conjunction with the modular energy system 2000. The accessories2029 can include, for example, a single-pedal footswitch 2032, adual-pedal footswitch 2034, and a cart 2030 for supporting the modularenergy system 2000 thereon. The footswitches 2032,2034 can be configuredto control the activation or function of particular energy modalitiesoutput by the energy module 2004, for example.

By utilizing modular components, the depicted modular energy system 2000provides a surgical platform that grows with the availability oftechnology and is customizable to the needs of the facility and/orsurgeons. Further, the modular energy system 2000 supports combo devices(e.g., dual electrosurgical and ultrasonic energy generators) andsupports software-driven algorithms for customized tissue effects. Stillfurther, the surgical system architecture reduces the capital footprintby combining multiple technologies critical for surgery into a singlesystem.

The various modular components utilizable in connection with the modularenergy system 2000 can include monopolar energy generators, bipolarenergy generators, dual electrosurgical/ultrasonic energy generators,display screens, and various other modules and/or other components, someof which are also described above in connection with FIGS. 1-3.

Referring now to FIG. 7A, the header module 2002 can, in some aspects,include a display screen 2006 that renders a GUI 2008 for relayinginformation regarding the modules 2001 connected to the header module2002. In some aspects, the GUI 2008 of the display screen 2006 canprovide a consolidated point of control of all of the modules 2001making up the particular configuration of the modular energy system2000. Various aspects of the GUI 2008 are discussed in fuller detailbelow in connection with FIG. 12. In alternative aspects, the headermodule 2002 can lack the display screen 2006 or the display screen 2006can be detachably connected to the housing 2010 of the header module2002. In such aspects, the header module 2002 can be communicablycouplable to an external system that is configured to display theinformation generated by the modules 2001 of the modular energy system2000. For example, in robotic surgical applications, the modular energysystem 2000 can be communicably couplable to a robotic cart or roboticcontrol console, which is configured to display the informationgenerated by the modular energy system 2000 to the operator of therobotic surgical system. As another example, the modular energy system2000 can be communicably couplable to a mobile display that can becarried or secured to a surgical staff member for viewing thereby. Inyet another example, the modular energy system 2000 can be communicablycouplable to a surgical hub 2100 or another computer system that caninclude a display 2104, as is illustrated in FIG. 11. In aspectsutilizing a user interface that is separate from or otherwise distinctfrom the modular energy system 2000, the user interface can bewirelessly connectable with the modular energy system 2000 as a whole orone or more modules 2001 thereof such that the user interface candisplay information from the connected modules 2001 thereon.

Referring still to FIG. 7A, the energy module 2004 can include a portassembly 2012 including a number of different ports configured todeliver different energy modalities to corresponding surgicalinstruments that are connectable thereto. In the particular aspectillustrated in FIGS. 6-12, the port assembly 2012 includes a bipolarport 2014, a first monopolar port 2016 a, a second monopolar port 2016b, a neutral electrode port 2018 (to which a monopolar return pad isconnectable), and a combination energy port 2020. However, thisparticular combination of ports is simply provided for illustrativepurposes and alternative combinations of ports and/or energy modalitiesmay be possible for the port assembly 2012.

As noted above, the modular energy system 2000 can be assembled intodifferent configurations. Further, the different configurations of themodular energy system 2000 can also be utilizable for different surgicalprocedure types and/or different tasks. For example, FIGS. 7A and 7Billustrate a first illustrative configuration of the modular energysystem 2000 including a header module 2002 (including a display screen2006) and an energy module 2004 connected together. Such a configurationcan be suitable for laparoscopic and open surgical procedures, forexample.

FIG. 8A illustrates a second illustrative configuration of the modularenergy system 2000 including a header module 2002 (including a displayscreen 2006), a first energy module 2004 a, and a second energy module2004 b connected together. By stacking two energy modules 2004 a, 2004b, the modular energy system 2000 can provide a pair of port assemblies2012 a, 2012 b for expanding the array of energy modalities deliverableby the modular energy system 2000 from the first configuration. Thesecond configuration of the modular energy system 2000 can accordinglyaccommodate more than one bipolar/monopolar electrosurgical instrument,more than two bipolar/monopolar electrosurgical instruments, and so on.Such a configuration can be suitable for particularly complexlaparoscopic and open surgical procedures. FIG. 8B illustrates a thirdillustrative configuration that is similar to the second configuration,except that the header module 2002 lacks a display screen 2006. Thisconfiguration can be suitable for robotic surgical applications ormobile display applications, as noted above.

FIG. 9 illustrates a fourth illustrative configuration of the modularenergy system 2000 including a header module 2002 (including a displayscreen 2006), a first energy module 2004 a, a second energy module 2004b, and a technology module 2040 connected together. Such a configurationcan be suitable for surgical applications where particularly complex orcomputation-intensive control algorithms are required. Alternatively,the technology module 2040 can be a newly released module thatsupplements or expands the capabilities of previously released modules(such as the energy module 2004).

FIG. 10 illustrates a fifth illustrative configuration of the modularenergy system 2000 including a header module 2002 (including a displayscreen 2006), a first energy module 2004 a, a second energy module 2004b, a technology module 2040, and a visualization module 2042 connectedtogether. Such a configuration can be suitable for endoscopic proceduresby providing a dedicated surgical display 2044 for relaying the videofeed from the scope coupled to the visualization module 2042. It shouldbe noted that the configurations illustrated in FIGS. 7A-11 anddescribed above are provided simply to illustrate the various conceptsof the modular energy system 2000 and should not be interpreted to limitthe modular energy system 2000 to the particular aforementionedconfigurations.

As noted above, the modular energy system 2000 can be communicablycouplable to an external system, such as a surgical hub 2100 asillustrated in FIG. 11. Such external systems can include a displayscreen 2104 for displaying a visual feed from an endoscope (or a cameraor another such visualization device) and/or data from the modularenergy system 2000. Such external systems can also include a computersystem 2102 for performing calculations or otherwise analyzing datagenerated or provided by the modular energy system 2000, controlling thefunctions or modes of the modular energy system 2000, and/or relayingdata to a cloud computing system or another computer system. Suchexternal systems could also coordinate actions between multiple modularenergy systems 2000 and/or other surgical systems (e.g., a visualizationsystem 108 and/or a robotic system 110 as described in connection withFIGS. 1 and 2).

Referring now to FIG. 12, in some aspects, the header module 2002 caninclude or support a display 2006 configured for displaying a GUI 2008,as noted above. The display screen 2006 can include a touchscreen forreceiving input from users in addition to displaying information. Thecontrols displayed on the GUI 2008 can correspond to the module(s) 2001that are connected to the header module 2002. In some aspects, differentportions or areas of the GUI 2008 can correspond to particular modules2001. For example, a first portion or area of the GUI 2008 cancorrespond to a first module and a second portion or area of the GUI2008 can correspond to a second module. As different and/or additionalmodules 2001 are connected to the modular energy system stack, the GUI2008 can adjust to accommodate the different and/or additional controlsfor each newly added module 2001 or remove controls for each module 2001that is removed. Each portion of the display corresponding to aparticular module connected to the header module 2002 can displaycontrols, data, user prompts, and/or other information corresponding tothat module. For example, in FIG. 12, a first or upper portion 2052 ofthe depicted GUI 2008 displays controls and data associated with anenergy module 2004 that is connected to the header module 2002. Inparticular, the first portion 2052 of the GUI 2008 for the energy module2004 provides first widget 2056 a corresponding to the bipolar port2014, a second widget 2056 b corresponding to the first monopolar port2016 a, a third widget 2056 c corresponding to the second monopolar port2016 b, and a fourth widget 2056 d corresponding to the combinationenergy port 2020. Each of these widgets 2056 a-d provides data relatedto its corresponding port of the port assembly 2012 and controls forcontrolling the modes and other features of the energy modalitydelivered by the energy module 2004 through the respective port of theport assembly 2012. For example, the widgets 2056 a-d can be configuredto display the power level of the surgical instrument connected to therespective port, change the operational mode of the surgical instrumentconnected to the respective port (e.g., change a surgical instrumentfrom a first power level to a second power level and/or change amonopolar surgical instrument from a “spray” mode to a “blend” mode),and so on.

In one aspect, the header module 2002 can include various physicalcontrols 2011 in addition to or in lieu of the GUI 2008. Such physicalcontrols 2011 can include, for example, a power button that controls theapplication of power to each module 2001 that is connected to the headermodule 2002 in the modular energy system 2000. Alternatively, the powerbutton can be displayed as part of the GUI 2008. Therefore, the headermodule 2002 can serve as a single point of contact and obviate the needto individually activate and deactivate each individual module 2001 fromwhich the modular energy system 2000 is constructed.

In one aspect, the header module 2002 can display still images, videos,animations, and/or information associated with the surgical modules 2001of which the modular energy system 2000 is constructed or the surgicaldevices that are communicably coupled to the modular energy system 2000.The still images and/or videos displayed by the header module 2002 canbe received from an endoscope or another visualization device that iscommunicably coupled to the modular energy system 2000. The animationsand/or information of the GUI 2008 can be overlaid on or displayedadjacent to the images or video feed.

In one aspect, the modules 2001 other than the header module 2002 can beconfigured to likewise relay information to users. For example, theenergy module 2004 can include light assemblies 2015 disposed about eachof the ports of the port assembly 2012. The light assemblies 2015 can beconfigured to relay information to the user regarding the port accordingto their color or state (e.g., flashing). For example, the lightassemblies 2015 can change from a first color to a second color when aplug is fully seated within the respective port. In one aspect, thecolor or state of the light assemblies 2015 can be controlled by theheader module 2002. For example, the header module 2002 can cause thelight assembly 2015 of each port to display a color corresponding to thecolor display for the port on the GUI 2008.

FIG. 13 is a block diagram of a stand-alone hub configuration of amodular energy system 3000, in accordance with at least one aspect ofthe present disclosure and FIG. 14 is a block diagram of a hubconfiguration of a modular energy system 3000 integrated with a surgicalcontrol system 3010, in accordance with at least one aspect of thepresent disclosure. As depicted in FIGS. 13 and 14, the modular energysystem 3000 can be either utilized as stand-alone units or integratedwith a surgical control system 3010 that controls and/or receives datafrom one or more surgical hub units. In the examples illustrated inFIGS. 13 and 14, the integrated header/UI module 3002 of the modularenergy system 3000 includes a header module and a UI module integratedtogether as a singular module. In other aspects, the header module andthe UI module can be provided as separate components that arecommunicatively coupled though a data bus 3008.

As illustrated in FIG. 13, an example of a stand-alone modular energysystem 3000 includes an integrated header module/user interface (UI)module 3002 coupled to an energy module 3004. Power and data aretransmitted between the integrated header/UI module 3002 and the energymodule 3004 through a power interface 3006 and a data interface 3008.For example, the integrated header/UI module 3002 can transmit variouscommands to the energy module 3004 through the data interface 3008. Suchcommands can be based on user inputs from the UI. As a further example,power may be transmitted to the energy module 3004 through the powerinterface 3006.

In FIG. 14, a surgical hub configuration includes a modular energysystem 3000 integrated with a control system 3010 and an interfacesystem 3022 for managing, among other things, data and powertransmission to and/or from the modular energy system 3000. The modularenergy system depicted in FIG. 14 includes an integrated headermodule/UI module 3002, a first energy module 3004, and a second energymodule 3012. In one example, a data transmission pathway is establishedbetween the system control unit 3024 of the control system 3010 and thesecond energy module 3012 through the first energy module 3004 and theheader/UI module 3002 through a data interface 3008. In addition, apower pathway extends between the integrated header/UI module 3002 andthe second energy module 3012 through the first energy module 3004through a power interface 3006. In other words, in one aspect, the firstenergy module 3004 is configured to function as a power and datainterface between the second energy module 3012 and the integratedheader/UI module 3002 through the power interface 3006 and the datainterface 3008. This arrangement allows the modular energy system 3000to expand by seamlessly connecting additional energy modules to energymodules 3004, 3012 that are already connected to the integratedheader/UI module 3002 without the need for dedicated power and energyinterfaces within the integrated header/UI module 3002.

The system control unit 3024, which may be referred to herein as acontrol circuit, control logic, microprocessor, microcontroller, logic,or FPGA, or various combinations thereof, is coupled to the systeminterface 3022 via energy interface 3026 and instrument communicationinterface 3028. The system interface 3022 is coupled to the first energymodule 3004 via a first energy interface 3014 and a first instrumentcommunication interface 3016. The system interface 3022 is coupled tothe second energy module 3012 via a second energy interface 3018 and asecond instrument communication interface 3020. As additional modules,such as additional energy modules, are stacked in the modular energysystem 3000, additional energy and communications interfaces areprovided between the system interface 3022 and the additional modules.

The energy modules 3004, 3012 are connectable to a hub and can beconfigured to generate electrosurgical energy (e.g., bipolar ormonopolar), ultrasonic energy, or a combination thereof (referred toherein as an “advanced energy” module) for a variety of energy surgicalinstruments. Generally, the energy modules 3004, 3012 includehardware/software interfaces, an ultrasonic controller, an advancedenergy RF controller, bipolar RF controller, and control algorithmsexecuted by the controller that receives outputs from the controller andcontrols the operation of the various energy modules 3004, 3012accordingly. In various aspects of the present disclosure, thecontrollers described herein may be implemented as a control circuit,control logic, microprocessor, microcontroller, logic, or FPGA, orvarious combinations thereof.

In one aspect, with reference to FIGS. 13 and 14, the modules of themodular energy system 3000 can include an optical link allowing highspeed communication (10-50 Mb/s) across the patient isolation boundary.This link would carry device communications, mitigation signals(watchdog, etc.), and low bandwidth run-time data. In some aspects, theoptical link(s) will not contain real-time sampled data, which can bedone on the non-isolated side.

In one aspect, with reference to FIGS. 13 and 14, the modules of themodular energy system 3000 can include a multi-function circuit blockwhich can: (i) read presence resistor values via A/D and current source,(ii) communicate with legacy instruments via hand switch Q protocols,(iii) communicate with instruments via local bus 1-Wire protocols, and(iv) communicate with CAN FD-enabled surgical instruments. When asurgical instrument is properly identified by an energy generatormodule, the relevant pin functions and communications circuits areenabled, while the other unused functions are disabled or disconnected,and set to a high impedance state.

In one aspect, with reference to FIGS. 13 and 14, the modules of themodular energy system 3000 can include a pulse/stimulation/auxiliaryamplifier. This is a flexible-use amplifier based on a full-bridgeoutput and incorporates functional isolation. This allows itsdifferential output to be referenced to any output connection on theapplied part (except, in some aspects, a monopolar active electrode).The amplifier output can be either small signal linear (pulse/stim) withwaveform drive provided by a DAC or a square wave drive at moderateoutput power for DC applications such as DC motors, illumination, FETdrive, etc. The output voltage and current are sensed with functionallyisolated voltage and current feedback to provide accurate impedance andpower measurements to the FPGA. Paired with a CAN FD-enabled instrument,this output can offer motor/motion control drive, while position orvelocity feedback is provided by the CAN FD interface for closed loopcontrol.

As described in greater detail herein, a modular energy system comprisesa header module and one or more functional or surgical modules. Invarious instances, the modular energy system is a modular energy system.In various instances, the surgical modules include energy modules,communication modules, user interface modules; however, the surgicalmodules are envisioned to be any suitable type of functional or surgicalmodule for use with the modular energy system.

Modular energy system offers many advantages in a surgical procedure, asdescribed above in connection with the modular energy systems 2000(FIGS. 6-12), 3000 (FIGS. 13-15). However, cable management andsetup/teardown time can be a significant deterrent. Various aspects ofthe present disclosure provide a modular energy system with a singlepower cable and a single power switch to control startup and shutdown ofthe entire modular energy system, which obviated the need toindividually activate and deactivate each individual module from whichthe modular energy system is constructed. Also, various aspects of thepresent disclosure provide a modular energy system with power managementschemes that facilitate a safe and, in some instances, concurrentdelivery of power to the modules of a modular energy system.

In various aspects, as illustrated in FIG. 15, a modular energy system6000 that is similar in many respects to the modular energy systems 2000(FIGS. 6-12), 3000 (FIGS. 13-15). For the sake of brevity, variousdetails of the modular energy system 6000, which are similar to themodular energy system 2000 and/or the modular energy system 3000, arenot repeated herein.

The modular energy system 6000 comprises a header module 6002 and an “N”number of surgical modules 6004, where “N” is an integer greater than orequal to one. In various examples, the modular energy system 6000includes a UI module such as, for example, the UI module 3030 and/or acommunication module such as, for example, the communication module3032. Furthermore, pass-through hub connectors couple individual modulesto one another in a stack configuration. In the example of FIG. 15, theheader module 6002 is coupled to a surgical module 6004 via pass-throughhub connectors 6005, 6006.

The modular energy system 6000 comprises an example power architecturethat consists of a single AC/DC power supply 6003 that provides power toall the surgical modules in the stack. The AC/DC power supply 6003 ishoused in the header module 6002, and utilizes a power backplane 6008 todistribute power to each module in the stack. The example of FIG. 15demonstrates three separate power domains on the power backplane 6008: aprimary power domain 6009, a standby power domain 6010, and an Ethernetswitch power domain 6013.

In the example illustrated in FIG. 15, the power backplane 6008 extendsfrom the header module 6002 through a number of intermediate modules6004 to a most bottom, or farthest, module in the stack. In variousaspects, the power backplane 6008 is configured to deliver power to asurgical module 6004 through one or more other surgical modules 6004that are ahead of it in the stack. The surgical module 6004 receivingpower from the header module 6002 can be coupled to a surgicalinstrument or tool configured to deliver therapeutic energy to apatient.

The primary power domain 6009 is the primary power source for thefunctional module-specific circuits 6013, 6014, 6015 of the modules6002, 6004. It consists of a single voltage rail that is provided toevery module. In at least one example, a nominal voltage of 60V can beselected to be higher than the local rails needed by any module, so thatthe modules can exclusively implement buck regulation, which isgenerally more efficient than boost regulation.

In various aspects, the primary power domain 6009 is controlled by theheader module 6002. In certain instances, as illustrated in FIG. 15, alocal power switch 6018 is positioned on the header module 6002. Incertain instances, a remote on/off interface 6016 can be configured tocontrol a system power control 6017 on the header module 6002, forexample. In at least one example, the remote on/off interface 6016 isconfigured to transmit pulsed discrete commands (separate commands forOn and Off) and a power status telemetry signal. In various instances,the primary power domain 6009 is configured to distribute power to allthe modules in the stack configuration following a user-initiatedpower-up.

In various aspects, as illustrated in FIG. 16, the modules of themodular energy system 6000 can be communicably coupled to the headermodule 6002 and/or to each other via a communication (Serialbus/Ethernet) interface 6040 such that data or other information isshared by and between the modules of which the modular energy system isconstructed. An Ethernet switch domain 6013 can be derived from theprimary power domain 6009, for example. The Ethernet switch power domain6013 is segregated into a separate power domain, which is configured topower Ethernet switches within each of the modules in the stackconfiguration, so that the primary communications interface 6040 willremain alive when local power to a module is removed. In at least oneexample, the primary communication interface 6040 comprises a 1000BASE-TEthernet network, where each module represents a node on the network,and each module downstream from the header module 6002 contains a 3-portEthernet switch for routing traffic to the local module or passing thedata up or downstream as appropriate.

Furthermore, in certain examples, the modular energy system 6000includes secondary, low speed, communication interface between modulesfor critical, power related functions including module power sequencingand module power status. The secondary communications interface can, forexample, be a multi-drop Local Interconnect Network (LIN), where theheader module is the master and all downstream modules are slaves.

In various aspects, as illustrated in FIG. 15, a standby power domain6010 is a separate output from the AC/DC power supply 6003 that isalways live when the supply is connected to mains power 6020. Thestandby power domain 6010 is used by all the modules in the system topower circuitry for a mitigated communications interface, and to controlthe local power to each module. Further, the standby power domain 6010is configured to provide power to circuitry that is critical in astandby mode such as, for example, on/off command detection, statusLEDs, secondary communication bus, etc.

In various aspects, as illustrated in FIG. 15, the individual surgicalmodules 6004 lack independent power supplies and, as such, rely on theheader module 6002 to supply power in the stack configuration. Only theheader module 6002 is directly connected to the mains power 6020. Thesurgical modules 6004 lack direct connections to the mains power 6020,and can receive power only in the stack configuration. This arrangementimproves the safety of the individual surgical modules 6004, and reducesthe overall footprint of the modular energy system 6000. Thisarrangement further reduces the number of cords required for properoperation of the modular energy system 6000, which can reduce clutterand footprint in the operating room.

Accordingly, a surgical instrument connected to surgical modules 6004 ofa modular energy system 6000, in the stack configuration, receivestherapeutic energy for tissue treatment that is generated by thesurgical module 6004 from power delivered to the surgical module 6004from the AC/DC power supply 6003 of the header module 6002.

In at least one example, while a header module 6002 is assembled in astack configuration with a first surgical module 6004′, energy can flowfrom the AC/DC power supply 6003 to the first surgical module 6004′.Further, while a header module 6002 is assembled in a stackconfiguration with a first surgical module 6004′ (connected to theheader module 6002) and a second surgical module 6004″ (connected to thefirst surgical module 6004′), energy can flow from the AC/DC powersupply 6003 to the second surgical module 6004″ through the firstsurgical module 6004′.

The energy generated by the AC/DC power supply 6003 of the header module6002 is transmitted through a segmented power backplane 6008 definedthrough the modular energy system 6000. In the example of FIG. 15, theheader module 6002 houses a power backplane segment 6008′, the firstsurgical module 6004′ houses a power backplane segment 6008″, and thesecond surgical module 6004″ houses a power backplane segment 6008″. Thepower backplane segment 6008′ is detachably coupled to the powerbackplane segment 6008″ in the stack configuration. Further, the powerbackplane 6008″ is detachably coupled to the power backplane segment6008′″ in the stack configuration. Accordingly, energy flows from theAC/DC power supply 6003 to the power backplane segment 6008′, then tothe power backplane segment 6008″, and then to the power backplanesegment 6008′″.

In the example of FIG. 15, the power backplane segment 6008′ isdetachably connected to the power backplane segment 6008″ viapass-through hub connectors 6005, 6006 in the stack configuration.Further, the power backplane segment 6008″ is detachably connected tothe power backplane segment 6008′″ via pass-through hub connectors 6025,6056 in the stack configuration. In certain instances, removing asurgical module from the stack configuration severs its connection tothe power supply 6003. For example, separating the second surgicalmodule 6004″ from the first surgical module 6004′ disconnects the powerbackplane segment 6008′″ from the power backplane segment 6008″.However, the connection between the power backplane segment 6008″ andthe power backplane segment 6008′″ remains intact as long as the headermodule 6002 and the first surgical module 6004′ remain in the stackconfiguration. Accordingly, energy can still flow to the first surgicalmodule 6004′ after disconnecting the second surgical module 6004″through the connection between the header module 6002 and the firstsurgical module 6004′. Separating connected modules can be achieved, incertain instances, by simply pulling the surgical modules 6004 apart.

In the example of FIG. 15, each of the modules 6002, 6004 includes amitigated module control 6023. The mitigated module controls 6023 arecoupled to corresponding local power regulation modules 6024 that areconfigured to regulate power based on input from the mitigated modulecontrols 6023. In certain aspects, the mitigated module controls 6023allow the header module 6002 to independently control the local powerregulation modules 6024.

The modular energy system 6000 further includes a mitigatedcommunications interface 6021 that includes a segmented communicationbackplane 6027 extending between the mitigated module controls 6023. Thesegmented communication backplane 6027 is similar in many respects tothe segmented power backplane 6008. Mitigated Communication between themitigated module controls 6023 of the header module 6002 and thesurgical modules 6004 can be achieved through the segmentedcommunication backplane 6027 defined through the modular energy system6000. In the example of FIG. 15, the header module 6002 houses acommunication backplane segment 6027′, the first surgical module 6004′houses a communication backplane segment 6027″, and the second surgicalmodule 6004″ houses a communication backplane segment 6027′″. Thecommunication backplane segment 6027′ is detachably coupled to thecommunication backplane segment 6027″ in the stack configuration via thepass-through hub connectors 6005, 6006. Further, the communicationbackplane 6027″ is detachably coupled to the communication backplanesegment 6027″ in the stack configuration via the pass-through hubconnectors 6025, 6026.

Although the example of FIG. 15 depicts a modular energy system 6000includes a header module 6002 and two surgical modules 6004′ 6004″, thisis not limiting. Modular energy systems with more or less surgicalmodules are contemplated by the present disclosure. In some aspects, themodular energy system 6000 includes other modules such as, for example,a communications module. In some aspects, the header module 6502supports a display screen such as, for example, the display 2006 (FIG.7A) that renders a GUI such as, for example, the GUI 2008 for relayinginformation regarding the modules connected to the header module 6002.The GUI 2008 of the display screen 2006 can provide a consolidated pointof control all of the modules making up the particular configuration ofa modular energy system.

FIG. 16 depicts a simplified schematic diagram of the modular energysystem 6000, which illustrates a primary communications interface 6040between the header module 6002 and the surgical modules 6004. Theprimary communications interface 6040 communicably connects moduleprocessors 6041, 6041′, 6041″ of the header module 6002 and the surgicalmodules 6004. Commands generated by the module processor 6041 of theheader module are transmitted downstream to a desired functionalsurgical module via the primary communications interface 6040. Incertain instances, the primary communications interface 6040 isconfigured to establish a two-way communication pathway betweenneighboring modules. In other instances, the primary communicationsinterface 6040 is configured to establish a one-way communicationpathway between neighboring modules.

Furthermore, the primary communications interface 6040 includes asegmented communication backplane 6031, which is similar in manyrespects to the segmented power backplane 6008. Communication betweenthe header module 6002 and the surgical modules 6004 can be achievedthrough the segmented communication backplane 6031 defined through themodular energy system 6000. In the example of FIG. 16, the header module6002 houses a communication backplane segment 6031′, the first surgicalmodule 6004′ houses a communication backplane segment 6031″, and thesecond surgical module 6004″ houses a communication backplane segment6031′″. The communication backplane segment 6031′ is detachably coupledto the communication backplane segment 6031″ in the stack configurationvia the pass-through hub connectors 6005, 6006. Further, thecommunication backplane 6031″ is detachably coupled to the communicationbackplane segment 6031″ in the stack configuration via the pass-throughhub connectors 6025, 6026.

In at least one example, as illustrated in FIG. 16, the primarycommunications interface 6040 is implemented using the DDS frameworkrunning on a Gigabit Ethernet interface. The module processors 6041,6041′, 6041″ are connected to Gigabit Ethernet Phy 6044, and GigabitEthernet Switches 6042′, 6042″. In the example of FIG. 16, the segmentedcommunication backplane 6031 connects the Gigabit Ethernet Phy 6044 andthe Gigabit Ethernet Switches 6042 of the neighboring modules.

In various aspects, as illustrated in FIG. 16, the header module 6002includes a separate Gigabit Ethernet Phy 6045 for an externalcommunications interface 6043 with the processor module 6041 of theheader module 6002. In at least one example, the processor module 6041of the header module 6002 handles firewalls and information routing.

Referring to FIG. 15, the AC/DC power supply 6003 may provide an ACStatus signal 6011 that indicates a loss of AC power supplied by theAC/DC power supply 6003. The AC status signal 6011 can be provided toall the modules of the modular energy system 6000 via the segmentedpower backplane 6008 to allow each module as much time as possible for agraceful shutdown, before primary output power is lost. The AC statussignal 6011 is received by the module specific circuits 6013, 6014,6015, for example. In various examples, the system power control 6017can be configured to detect AC power loss. In at least one example, theAC power loss is detected via one or more suitable sensors.

Referring to FIGS. 15 and 16, to ensure that a local power failure inone of the modules of the modular energy system 6000 does not disablethe entire power bus, the primary power input to all modules can befused or a similar method of current limiting can be used (e-fuse,circuit breaker, etc.). Further, Ethernet switch power is segregatedinto a separate power domain 6013 so that the primary communicationsinterface 6040 remains alive when local power to a module is removed. Inother words, primary power can be removed and/or diverted from asurgical module without losing its ability to communicate with othersurgical modules 6004 and/or the header module 6002.

Backplane Connector Attachment Mechanism for Modular Energy System

Having described a general implementation the header and modules ofmodular energy systems 2000, 3000, 6000, and various surgicalinstruments usable therewith, for example, surgical instruments 2204,2206, and 2208, the disclosure now turns to describe various aspects ofmodular energy systems comprising backplane connector attachmentmechanisms. In other aspects, these modular energy systems aresubstantially similar to the modular energy system 2000, the modularenergy system 3000, and/or the modular energy system 6000 describedhereinabove. For the sake of brevity, various details of the othermodular energy systems being described in the following sections, whichare similar to the modular energy system 2000, the modular energy system3000, and/or the modular energy system 6000, are not repeated herein.Any aspect of the other modular energy systems described below can bebrought into the modular energy system 2000, the modular energy system3000, or the modular energy system 6000.

As described hereinbelow with reference to FIGS. 17-43, in variousaspects, the present disclosure provides modular energy systems 2000,3000, 6000 comprising backplane connector attachment mechanisms. In oneaspect, the present disclosure provides modular energy systems 2000,3000, 6000 comprising mechanical attachment features for a backplaneconnector. In another aspects, the present disclosure provides modularenergy systems 2000, 3000, 6000 comprising energy module bridgeconnectors. In yet another aspect, the present disclosure providesmodular energy systems 2000, 3000, 6000 comprising modular energybackplane connector internal flex circuits. In one aspect, the presentdisclosure provides modular energy systems 2000, 3000, 6000 comprisingmechanical attachment of a backplane connector of a back panel. Inanother aspect, the present disclosure provides modular energy systems2000, 3000, 6000 comprising enclosures to fasten backplanes. In anotheraspect, the present disclosure provides modular energy systems 2000,3000, 6000 comprising crush ribs to capture backplane housings. In yetanother aspect, the present disclosure provides modular energy systems2000, 3000, 6000 comprising back panel support for backplanes. In yetanother aspect, the present disclosure provides modular energy systems2000, 3000, 6000 comprising isolating features for modular energysystems 2000, 3000, 6000.

Mechanical Attachment Feature of the Modular Energy System BackplaneConnector

Having described a general implementation of a modular energy systems2000, 3000, 6000, the disclosure now turns to various aspects of thebackplane connector of the modular energy systems 2000, 3000, 6000. Inone aspect, the below described backplane connector can be added to anymodule of any of the modular energy systems 2000, 3000, 6000accommodating modules of varying heights. In another aspect, the backplane connector can be built into a module enclosure. In another aspectthe back plane connector can electrically and physically connect stackedmodules of any of the modular energy systems 2000, 3000, 6000 with lowprofile cabling. In another aspect, the back plane connector can beattached to a module of any of the modular energy systems 2000, 3000,6000 with snapping features.

The modular energy system can have multiple modules stacked on top ofone another. The modules of the module energy system may contain abackplane connector subassembly that physically and electrically connectthe stacked modules. In one aspect, each backplane connector subassemblymay be required to withstand the weight of two modules, which couldoccur due to misalignment by the user when stacking a module.Accordingly, to withstand the weight of two modules the backplaneconnectors may require a robust attachment that can withstand theweight. Additionally, in one aspect, the backplane connector subassemblymay be required to be adapted to different heights of future moduleswithout modifying the connector design. Additionally, the attachmentfeatures may be required to not be visible from the outside of the unitto maintain an ideal aesthetic.

The back panel of the backplane connector subassembly could have, in oneaspect, support members attached to it. The support members could beused to attach the upstream and downstream connectors via mating holesin the sides of each connector. The back panel attachment features orsupport members, in one aspect, could be fastener inserts that areattached to a sheet metal back panel. Such fastener inserts includeinserts manufactured by PennEngineering known under the tradename PEM.Such fasteners include any one or more fasteners that utilizeself-clinching, broaching, flaring, surface mount, or weld technology toprovide strong, reusable, and permanent threads and mounting points inthin sheet metal, PCB materials, and other ductile or non-ductile thinmaterial, for example. The upstream connector once attached may haveribs that extend down and may touch off on square fastener inserts, forexample support ledges, attached to the back panel for added mechanicalsupport.

In one aspect, fastener inserts are designed to be used for attachingcomponents via threads, zip ties, etc. so this is a non-traditional wayto use these inserts. From a Preliminary Finite Element Analysis thedesign may withstand loads of at least 60 lbs without yielding. In oneaspect, by using fastener inserts to attach the support members to thepanel, the attachment to the panel is nearly invisible from the rear ofthe panel which satisfies aesthetic requirements. The design may beadaptable for future modules as the support members can be attached to asheet metal back panel of another module without the need to modify thebackplane connectors themselves.

In one aspect, FIGS. 17-19 show a backplane connector subassembly 343.Referring primarily to FIG. 17, the back panel 202 has 2 sets of supportmembers attached to the inner surface 208 of the back panel 202. A firstset of support members 212, 214 to attach an upstream connector 200 anda second set of support members 220, 222 to attach a downstreamconnector 280. In one aspect, there could be 4 support members to attachthe upstream and downstream connectors, such as support members 212,214, 220, 222. In another aspect, there could be any number of supportmembers used to attach the upstream and down connectors, such as 1support member for the upstream and 1 support member for the downstream.

Referring primarily to FIG. 19, the support members 212, 214, 220, 222are attached to and extending away from the back panel 202. For example,the support members 212, 214, 220, 222 could be fastener inserts thatare attached to a surface 208 of the back panel 202. In one aspect, thesupport members could extend perpendicularly away from the back panel202. In other aspects, the support members 212, 214, 220, 222 couldextend away at any angle from the back panel 202. Support ledges 216,218 may be attached to the back panel 202 between the first set ofsupport members 212, 214 and the second set of support members 220 222.The support ledges 216, 218 may be offset from the first set of supportmembers 212, 214. The back panel 202 may have vent holes 224 to allowair flow into the module. Additionally the back panel 202 may have sideedges 226 to allow the back panel to be attached to the enclosure of themodule.

Referring to FIGS. 17 and 18, the upstream connector 200 can attach tothe back panel 202 by sliding mating holes onto support members 212,214. The downstream connector 254 attaches to the back panel 202 by asimilar means as the upstream connector 200. For example, the downstreamconnector 254 can attach to the back panel 202 by sliding mating holesonto the support members 220, 222. FIG. 17 shows the upstream connector200 and the downstream connector 254 detached from the back panel 202.FIG. 18 shows the upstream connector 200 and the downstream connector254 attached to the back panel 202.

Still referring to FIGS. 17 and 18, the upstream connector 200 mayattach to the back panel 202 by sliding mating holes onto supportmembers 212, 214 of the back panel 202. The mating holes may be locatedon the lower portion 260 of the upstream connector 200, for examplethere may be a mating hole located in each protrusions 262, 264. Thehousing 234 may extend away from the lower portion 260 ending in theupper portion 232. Referring primarily to FIG. 18, when the upstreamconnector 200 is attached to the back panel 202 a portion of the housing234 and upper portion 232 extends past the top edge 204 of the backpanel 202. A hole 240 is where the electrical components may pass fromthe module above in the stack to the physically connected module belowin the stack. Power and electrical communications may pass between thetwo modules. Support ribs 236, 238 can extend away from the lowerportion 260 in the opposite direction of the housing 234. The supportrib 236 may attach to the upstream connector 200 at the protrusion 264and the support rib 238 may attach to the upstream connector 200 at theprotrusion 262. Referring primarily to FIG. 18, when the upstreamconnector 200 is attached to the back panel 202, the support ribs 236,238 may rest on the support ledges 216, 218. The support rib 236 mayrest on the support ledge 216 and the support rib 238 may rest on thesupport ledge 218. It is noted that a design without the support ribsmay also be possible.

Still referring to FIGS. 17 and 18, the downstream connector 254 mayattach to the back panel 202 by sliding mating holes onto supportmembers 220, 222 of the back panel 202. The mating holes may be locatedin the protrusions 278, 280. The housing 274 may extend away from theprotrusions 278, 280. Referring primarily to FIG. 18, when thedownstream connector 254 is attached to the back panel 202, the bottom290 of the downstream connector 254 may align with the bottom edge 206of the back panel 202. The hole 276 is where the electrical componentsmay pass through the module to the next module down in the stack. Thedownstream connector 254 may have a cavity 272 at the bottom surface 290of the downstream connector 254. The cavity 272 may be made to mate withthe upper portion 232 of an upstream connector during stacking ofmodules.

When stacking a module the upper portion 232 of the upstream connector200 of the lower module may enter the cavity 272 of the downstreamconnector 254 located in the upper module to electrically and physicallyconnect the two modules. For example, when the modules are stacked theupper portion 232 may enter the cavity 272 and a plug inside of thedownstream connector 254 may enter the hole 240 and connect with a pluginside of the upstream connector 200 to electrically connect themodules. In one aspect, the plug may be integrated into the connectorassembly such that it is one molded component and not two separatecomponents. In another aspect, the plug could be a separate componentinserted into the connector. In yet another aspect, electricalpins/contacts may be integrated into the connector, for example pressedinto. In one aspect, electrical wires may start at the plug inside ofthe upstream connector 230 and terminate at a printed circuit board inthe module. In one aspect, similarly, electrical wires may start at theplug inside of the downstream connector 270 and terminate at a printedcircuit board in the module. Multiple modules can be stacked on top ofone another no matter the height of the module. Each module may have thesame upstream connector 200 and downstream connector 254, which mayallow the modules to be physically and electrically connected when themodules are stacked. When the modules are stacked and connected, powermay transfer through the upstream connector 200 into the module and thenthrough the downstream connector 254 to the next module lower in thestack. Electrical communications can pass through the upstream connector200 and downstream connector 254 both ways.

To better understand the stacking the following is an example ofstacking 3 modules. A first module can be on the bottom of the stack, asecond module can be in the middle of the stack, and a third module canbe on the top of the stack. The second module may be stacked on top ofthe first module. Then the upper portion 232 of the upstream connector200 of the first module may enter the cavity 272 of the downstreamconnector 254 of the second module. The first and second modules maythen be physically and electrically connected. Then the third module maybe stacked on top of the second module. Then the upper portion 232 ofthe upstream connector 200 of the second module may enter the cavity 272of the downstream connector 254 of the third module. The first, second,and third modules may then be physically and electrically connected. Theupstream connector 200 and downstream connector 254 can be the same ineach module. The height of the modules may vary since the upstreamconnector 200 and the downstream connector 254 are connected to the backpanel 202 of the modules themselves.

Mechanical Attachment Feature of Backplane Connector

FIGS. 20-29 show different views of an alternate backplane connectorsubassembly 345 that is substantially similar to the back planeconnector subassembly 343 of FIGS. 17-19. FIG. 20 shows an alternativeupstream connector 230 that may be substantially similar to upstreamconnector 200. For the sake of brevity, not all of the details that arethe same will be reiterated. The upstream connector 230 may comprise anupper portion 232, a hole 240, a housing 234, a lower portion 260, twoprotrusions 262, 264, and holes that mate with support members 212, 214,where each of these features are the substantially similar to theupstream connector 200. The upstream connector 230 may have a hole 244located on the surface 258 of protrusion 262 and a hole 242 located onthe surface 256 of the protrusion 264. The surface 256 may be offsetfrom the housing 234 by a distance d1, and the surface 258 may be offsetthe same distance d1 from the housing 234. The upstream connector 230may comprise 4 support ribs that extend away from the lower portion 260.There may be two support ribs 246, 248 that extend away from theprotrusion 262 and two support ribs 250, 252 that extend away from theprotrusion 264. A hole 240 is where the electrical components may passfrom the module above in the stack to the physically connected modulebelow in the stack.

FIG. 21 shows an alternate downstream connector 270 that may besubstantially similar to downstream connector 254. For the sake ofbrevity, not all of the details that are the same will be reiterated.The downstream connector 270 may comprise a housing 274, two protrusions278, 280, a cavity 272, and holes that mate with support members 220,222, where each of these features are substantially similar to thedownstream connector 254. The downstream connector 270 may have a hole286 located on a surface 284 of protrusion 280 and a hole 288 located ona surface 282 of the protrusion 278. The surface 282 may be offset fromthe housing 274 by a distance d2, and the surface 258 may be offset thesame distance d2 from the housing 274. Hole 276 is where the electricalcomponents may pass from the current module the stack to the physicallyconnected module below in the stack. The downstream connector 270 mayhave a bottom surface 290 and on that surface there may be a cavity 272.The cavity 272 may be made to mate with the upper portion 232 of theupstream connector 230 during module stacking. In one aspect, when themodules are stacked the downstream connector 270 of the upper modulemates with the upstream connector 230 of the lower module to physicallyand electrically connect the two modules. For example, when thedownstream connector 270 and the upstream connector 230 are mated thehole 240 and hole 276 allow electrical components to connect between theupper module and the lower module.

FIG. 22 shows an alternate back panel 210 that may be substantiallysimilar to downstream connector 254. For the sake of brevity, not all ofthe details that are the same will be reiterated. The back panel 210 mayhave a top edge 204, a bottom edge 206, a first set of support members212, 214, a second set of support members 220, 222, a surface 208, sideedges 226, vent holes 224, and support ledges 216, 218, where each ofthese features are substantially similar to the back panel 202. Thesupport ledges 216, 218 may be attached to the surface 208 between thefirst set of support members 212, 214 and the second set of supportmembers 220, 222. In one aspect, the support ledges 216, 218 may beattached closer to the first set of support members 212, 214 than thesecond set of support members 220, 222. In one aspect, the supportmembers 212, 214, 220, 222 could extend perpendicularly away from theback panel 202. In other aspects, the support members 212, 214, 220, 222could extend away at any angle from the back panel 202.

Referring to FIG. 23, the upstream connector 230 and the downstreamconnector 270 are connected to the back panel 210. The upstreamconnector 230 may be attach to the back panel 210 by sliding the holes242, 244 onto the support members 212, 214. For example, the hole 242slides onto the support member 212 and the hole 244 slides onto thesupport member 214. For example, the upstream connector 230 may slidethe holes 242, 244 onto the support members 212, 214 such that thesurfaces 256, 258 touch surface 208. Once the upstream connector 230 isslide onto the support members 212, 214 the upstream connector 230 maybe attached to the back panel 210. The support ribs 246, 248, 250, 252may rest on the support ledges 216, 218 once the upstream connector 230is attached to the back panel 210. For example, the support ribs 250,252 may rest on support ledge 216 and the support ribs 246, 248 may reston the support ledge 218. In one aspect, the support ribs 246, 248, 250,252 provide additional physical support when modules are stacked. Theupstream connector 230 may have upper portion 232 that extends past thetop edge 204 of the back panel 210. A hole 240 is where the electricalcomponents may pass from the module above in the stack to the physicallyconnected module below in the stack.

Still referring to FIG. 23, the downstream connector 270 may be attachto the back panel 210 by sliding the holes 288, 286 onto the supportmembers 220, 222. For example, the hole 288 slides onto the supportmember 220 and the hole 286 slides onto the support member 222. Forexample, the downstream connector 270 may slide the holes 288, 286 ontothe support members 220, 222 such that the surfaces 282, 284 touchsurface 208. Once the downstream connector 270 is slide onto the supportmembers 220, 222, the downstream connector 270 may be attached to theback panel 210. The downstream connector 270 may have a surface 290 thataligns with the bottom edge 206 such that nothing extends past thebottom edge 206 of the back panel 210. The hole 276 is where theelectrical components from the current module may pass to the nextmodule below in the stack.

FIG. 24 shows a back view of the back panel 210 shown in FIG. 23. Statedanother way FIG. 24 shows the view of the back of the module from theoutside, where FIG. 23 shows the view of the back panel 210 from theinside of the module. Referring to FIG. 24, the upper portion 232 mayextend past the top edge 204 of the back panel 210. The indents 212 a,214 a may be all that is seen from the outside of the module from theattachment of the support members 212, 214. The indents 216 a, 218 a maybe all that is seen from the outside of the module from the attachmentof the support ridges 216, 218. The indents 220 a, 222 a may be all thatis seen from the outside of the module of the attachment of the supportmembers 220, 222. From the outside of the module, the downstreamconnector 270 may not be seen.

FIGS. 25-27 show some of the wires of the back plane connectorsubassembly. Referring to FIGS. 25 and 26, in one aspect, the electricalwires 294 may come down from a plug inside of the upstream connector 230and terminate at plug 296. In one aspect, the electrical wires 294 canbe used to send data between the stacked modules, for example sendingdata back and forth from the module higher in the stack to the currentmodule. Referring to FIG. 27, the electrical wires 304 may come downfrom a plug inside of the upstream connector 230 and terminate at plug296. In one aspect, the electrical wires 304 can be used to send databetween the stacked modules, for example sending data back and forthfrom the module higher in the stack to the current module. Referring toFIGS. 25 and 26, the electrical wires 292 may come from a plug inside ofthe downstream connector 270 and terminate at the plug 296. In oneaspect, the electrical wires 292 can be used to send data between thestacked modules, for example sending data back and forth from the modulelower in the stack to the current module. Referring to FIGS. 28 and 29,a printed circuit board 306 for the module may connect with plug 296. Inone aspect, the printed circuit board 306 controls the module andreceives the transmits signals through the sets of wires 294, 304, 292.For example, the printed circuit board may be able to send data to andfrom the modules that are stacked above and below the current module.Referring to FIGS. 25-29, the electrical wire 298 and the electricalwire 300 may come from a plug in the upstream connector 230 andterminate at plug 302. In one aspect, the electrical wires 298 and 300can be used to transport power to the current module.

When stacking a module, the upper portion 232 of the upstream connector230 of the lower module may enter a cavity 272 of the downstreamconnector 270 located in the upper module electrically and physicallyconnecting the two modules. In one aspect, a plug inside of the upstreamconnector 230 may connect with a plug inside of the downstream connector270 to electrically connect the modules that are stacked. For example,when the modules are stacked the upper portion 232 may enter the cavity272 and a plug inside of the downstream connector 270 may enter the hole240 and connect with a plug inside of the upstream connector 230 toelectrically connect the modules. In one aspect, the plug may beintegrated into the connector assembly such that it is one moldedcomponent and not two separate components. In another aspect, the plugcould be a separate component inserted into the connector. In yetanother aspect, electrical pins/contacts may be integrated into theconnector, for example pressed into. In one aspect, electrical wires maystart at the plug inside of the upstream connector 230 and terminate ata printed circuit board in the module. In one aspect, similarly,electrical wires may start at the plug inside of the downstreamconnector 270 and terminate at a printed circuit board in the module.Multiple modules can be stacked on top of one another no matter theheight the modules. Each module may have the same upstream connector 230and downstream connector 270, which allow the modules to be physicallyand electrically connected when the modules are stacked. When themodules are stacked and connected, power transfers through the upstreamconnector 230 into the module and then through the downstream connector270 to the next module lower in the stack. Electrical communications canpass through the upstream connector 230 and downstream connector 270both ways.

To better understand the stacking, the following is an example ofstacking 3 modules. A first module can be on the bottom of the stack, asecond module can be in the middle of the stack, and a third module canbe on the top of the stack. The second module may be stacked on top ofthe first module. Then the upper portion 232 of the upstream connector230 of the first module may enter the cavity 272 of the downstreamconnector 270 of the second module. The first and second modules maythen be physically and electrically connected. Then the third module maybe stacked on top of the second module. The upper portion 232 of theupstream connector 230 of the second module may enter the cavity 272 ofthe downstream connector 270 of the third module. The first, second, andthird modules may then be physically and electrically connected. Theupstream connector 230 and downstream connector 270 can be the same ineach module. The height of the modules may vary since the upstreamconnector 230 and the downstream connector 270 are connected to the backpanel 210 of the modules themselves.

Energy Module Bridge Connector

In various aspects, an end user is permitted to assemble any suitablenumber of modules into a variety of different stacked configurationsthat support electrical energy flow therebetween. Each of the differenttypes of modules provides different functionality, thereby allowingindividuals to customize the functions provided by each surgicalplatform by customizing the modules that are included in each surgicalplatform. The modular energy system is assembled or is modified by anend user either prior to or during a surgical procedure. Since themanufacturer is not involved with the final assembly of a modular energysystem, suitable precautions are taken to ensure proper stacking of anassembled modular energy system and/or alignment of modules within themodular energy system.

As discussed above, the one or more modules can be connected together ina variety of different stacked configurations to form various modularenergy systems. When positioned in the variety of different stackedconfigurations, the surgical modules are configured to communicate andtransmit power therebetween. It is contemplated that external wiringconnections can be utilized in order to electrically couple the moduleswhen stacked together to facilitate the transmission of communicationsignals and power. However, it is desirable that the modules beconnectable together without the need for external wiring to facilitatesafe assembly and disassembly by an end user. To that end, the modulescan include bridge connectors that are configured to transmit powerand/or communication signals between the modules in the modular energysystem when the modules are assembled or engaged together.

In one general aspect, the present disclosure provides a connectorpositioned on the top and a socket on the bottom of a stackable energymodule, which can carry communication and power through multiple units(i.e., modules). The connector shape facilitates mechanical alignment,then grounding, then electrical contact of a series of power andcommunication lines when multiple energy modules are assembled togetherinto a modular energy system.

In another general aspect, the present disclosure provides a bridgecircuit that is segmented into identical boards residing within eachmodule and is connected by connectors shaped to align and connect avariable number of stacked modules together (including a header module).

In another general aspect, the present disclosure provides a moduleconnector configured to have a first or stowed configuration and secondor extended configuration. The modular connectors for energy modules(and/or other modules of a modular energy system) can carry bothcommunication and power between modules, where the connector isconfigured to be transitioned between the stowed configuration, whichhas a first low profile, and the extended configuration, which providesfor both an electrical and mechanical connection between modules.

In yet another general aspect, the present disclosure provides asurgical platform comprising a first surgical module and a secondsurgical module. The first surgical module is configured to be assembledin a stack configuration with the second surgical module. The firstsurgical module includes a first bridge connector portion, whichcomprises a first outer housing and first electrical connectionelements. The second surgical module comprises a second bridge connectorportion, which comprises a second outer housing and second electricalconnection elements. The second outer housing is shaped and configuredto engage the first outer housing during the assembly before secondelectrical connection elements engage the first electrical connectionelements.

In yet another general aspect, the present disclosure provides asurgical platform comprising a first surgical module and a secondsurgical module. The first surgical module comprises a first enclosurecomprising a bottom surface, a first bridge connector, wherein the firstbridge connector comprises a recess, a first printed circuit board(PCB), and a first wire assembly connected to the first PCB. The firstwire assembly extends from the first PCB to the first bridge connectorand the first wire assembly is operably coupled to the first bridgeconnector. The second surgical module comprises a second enclosurecomprising a top surface, a second bridge connector, a second PCB, and asecond wire assembly connected to the second PCB. The second bridgeconnector extends away from the top surface and the second bridgeconnector is configured to be positioned in the recess of the firstbridge connector of the first surgical module. The second wire assemblyextends from the second PCB to the second bridge connector and thesecond wire assembly is operably coupled to the second bridge connector.When the second bridge connector is positioned in the first bridgeconnector, the second wire assembly is electrically coupled with thefirst wire assembly.

Referring now to FIGS. 30 and 31, a configuration is shown in whichthree surgical modules, a first module 10002, a second module 10004, anda third module 10006, are assembled together in a stacked configurationby an end user utilizing an internal wiring arrangement to facilitatethe transmission of communication signals and power between modules in amodular energy system 10000. Each module 10002, 10004, and 10006, can bethe same type of surgical module or different types of surgical modules.For example, each module 10002, 10004, and 10006, can be a headermodule, an energy module, a generator module, an imaging module, a smokeevacuation module, a suction/irrigation module, a communication module,a processor module, a storage array, a surgical device coupled to adisplay, a non-contact sensor module, or other modular device. These andother such modules are described above under the headings SURGICAL HUBSand MODULAR ENERGY SYSTEM.

Each module 10002, 10004, and 10006, can include a bridge connector. Forexample, the first module 10002 can comprise a lower bridge connector10008, the second module 10004 can comprise an upper bridge connector10010 (FIG. 32) and a lower bridge connector 10012, and the third module10006 can comprise an upper bridge connector (not shown) and a lowerbridge connector 10016. Each bridge connector, 10008, 10010, 10012, and10016, can include an outer housing extending at least partially aroundelectrical connection elements of the respective bridge connector.

Referring to FIG. 32, a detailed view of an aspect of the second module10004 is provided. It is understood the first module 10002 and the thirdmodule 10006 can be configured as the second module 10004 illustrated inFIG. 32. The upper bridge connector 10010 of the second module 10004 ismounted to a top surface 10018 a of the enclosure 10018 and extends awayfrom the second module 10004. The lower bridge connector 10012 of thesecond module 10004 is mounted to the bottom surface 10018 b of theenclosure 10018 of the second module 10004. The lower bridge connector10012 includes a recess 10020 that is shaped and configured to receivean upper bridge connector from a separate module. For example, when thesecond module 10004 is stacked on top of the third module 10006, theupper bridge connector of the third module 10006 is inserted into therecess 10020 of the lower bridge connector 10016 of the second module10004, thus, aligning the second module 10004 with the third module10006.

Referring to back to FIGS. 30 and 31, each module, 10002, 10004, and10006, further includes a PCB. For example, the first module 10002includes a first PCB 10022, the second module 10004 includes a secondPCB 10024, and the third module 10006 includes a third PCB 10026.

Additionally, each module, 10002, 10004, and 10006, includes a flexiblewire harness (e.g., flexible cable) electrically connected to therespective PCB, 10022, 10024, and 10026, by any suitable number ofconnections. For example, the first module 10002 includes a firstflexible wire harness 10028 extending from the first PCB 10022 andoperably coupled to the lower bridge connector 10008 of the first module10002 to connect the first PCB 10022 with electrical connection elementsof the lower bridge connector 10008. The first flexible wire harness10028 is positioned within the first module 10002 and, thus, mayfacilitate quicker assembly of a modular energy system.

The second module 10004 includes a second flexible wire harness 10030and a third flexible wire harness 10032 extending from the second PCB10024. The second flexible wire harness 10030 is operably coupled to theupper bridge connector 10010 of the second module 10004 to connect thesecond PCB 10024 with electrical connection elements of the upper bridgeconnector 10010. The third flexible wire harness 10032 is operablycoupled to the lower bridge connector 10012 of the second module 10004to connect the second PCB 10024 with electrical connection elements ofthe lower bridge connector 10012. The second and third flexible wireharnesses 10030 and 10032 are positioned within the second module 10002and, thus, may facilitate quick assembly of a modular energy system.

The third module 10006 includes a fourth flexible wire harness 10034 anda fifth flexible wire harness 10036 extending from the third PCB 10026.The fourth flexible wire harness 10034 is operably coupled to the upperbridge connector of the third module 10006 to connect the third PCB10026 with electrical connection elements of the upper bridge connectorof the third module 10006. The fifth flexible wire harness 10036 isoperably coupled to the lower bridge connector 10016 of the third module10006 to connect the third PCB 10026 with the electrical connectionelements of the lower bridge connector 10016. The fourth and fifthflexible wire harnesses 10034 and 10036 are positioned within the thirdmodule 10002 and thus, may facilitate quick assembly of a modular energysystem.

When an upper bridge connector of a lower module is positioned in alower bridge connector of an upper module (e.g., the electricalconnection elements of the bridge connectors are electrically coupled),the upper flexible wire harness connected to the upper bridge connectorof the lower module is electrically coupled with the lower flexible wireharness connected to the lower bridge connector of the upper module.When coupled, power and communication signals are able to flow from thelower module to the upper module (and/or from the upper module to thelower module) by way of the internal flexible wire harnesses and thePCBs. For example, when the upper bridge connector 10014 of the thirdmodule 10006 is positioned in the lower bridge connector 10012 of thesecond module 10004, the fourth flexible wire harness 10034 iselectrically coupled with the third flexible wire harness 10032. Thus,power and communications signals are able to flow from the third module10006 to the second module 10004 by way of the third and fourth flexiblewire harnesses, 10032 and 10034, and the respective PCBs, 10023 and10026.

Referring back to FIGS. 30-32, in one instance, a board connector 10038is mounted on the second PCB 10024 and a board connector 10066 ismounted on the third PCB 10026. The second flexible wire harness 10030is configured to extend from the upper bridge connector 10010 andconnect to the board connector 10038, while the third flexible wireharness 10032 is configured to extend from the lower bridge connector10012 and connect to the board connector 10038. The fourth flexible wireharness 10034 is configured to extend from the upper bridge connector ofthe third module 10006 and connect to the board connector 10066, whilethe fifth flexible wire harness 10036 is configured to extend from thelower bridge connector 10016 and connect to the board connector 10066.

Similar to the scenario described above, when an upper module isconnected with a lower module by way of respective bridge connectors,the upper and lower modules are able to communicate and transmit powertherebetween by way of the PCBs, the board connectors, and the flexiblewire harnesses. For example, referring to FIG. 31, power andcommunications signals are able to flow from the third module 10006 tothe second module 10004 by way of the third and fourth flexible wireharnesses, 10032 and 10034, the board connectors, 10038 and 10066, andthe respective PCBs, 10024 and 10026.

Referring now to FIG. 33, a separate aspect of a module 10040 is shown.The module 10040 illustrated in FIG. 33 is similar in many respects tothe second module 10004 shown and described in FIGS. 30-32. However,instead of a flexible wire harness, a rigid wire harness 10042 isutilized. The rigid wire harness 10042 can be sized and configured tostand between a top surface 10044 a of an enclosure 10044 of the module10040 and a bottom surface 10044 b of the enclosure 10044 of the module10040. The rigid wire harness 10042 can extend the full, or at leastsubstantially the full, height, h₁, of the module 10040. Further, theupper and lower bridge connectors, 10046 and 10048, are operably coupled(e.g., directly mated) to the rigid wire harness 10042 rather than tothe enclosure 10044 of the module 10040. In at least one example, theupper and lower bridge connectors, 10046 and 10048, are integrated withthe rigid wire harness 10042.

In the example of FIG. 33, upper wires 10050 extend from a boardconnector 10054 on the PCB 10056, along the rigid wire harness 10042,and connect to the upper bridge connector 10046. In addition, lowerwires 10052 extend from the board connector 10054 and connect to thelower bridge connector 10048. The lower bridge connector 10048 includesa recess 10062 that is shaped and configured to receive an upper bridgeconnector from a separate module.

A series of holding members 10058 can extend from the rigid wire harness10042, which are configured to wrap, or at least partially wrap, aroundthe upper wires 10050 to support the upper wires 10050 within apredetermined distance from the rigid wire harness 10042. In the exampleof FIG. 33, the holding members 10058 extend from a backbone column10060 that supports the upper and lower bridge connectors, 10046 and10048.

The ability to mate the rigid wire harness 10042 with the upper bridgeconnector 10046 and lower bridge connector 10048 provides a distinctadvantage when assembling the module 10040. As the rigid wire harness10042 is one piece and extends the full, or at least substantially thefull, height, h₁, of the module 10040, the rigid wire harness 10042 canbe inserted into the module 10040 during assembly of the module 10040and stand free. Once assembled into the module 10040, the upper andlower bridge connecters, 10046, 10048, can be mated directly with therigid wire harness 10042, thereby eliminating the need to mount theupper and lower bridge connectors, 10046, 10048, to the top and bottomsurfaces, 10044 a, 10044 b, of the enclosure 10044, respectively, thus,reducing assembly time. The rigid wire harness 10042 can limit forceapplied to an enclosure 10044 of the module 10040 during assembly of amodular energy system and can reliably establish and/or maintainconnections between bridge connectors.

Modular Energy Backplane Connector Internal Flex Circuit

In a general aspect, the modular energy backplane upstream connector anddownstream connector may need to electrically connect to the module inan area where space is limited. In another general aspect, theelectrical connection may be required to be flexible to accommodatefuture modules that may be different heights. In one aspect, thebackplane upstream and downstream connectors can electrically connectsto the module via a flex ribbon cable which is low profile and spaceefficient.

In one general aspect, the backplane connector subassembly 345 mayrequire the upstream connector 230 and downstream connector 270 toelectrically connect into the main printed circuit board of the modulein a way that is space efficient and flexible in height to accommodatefuture modules of different heights. Referring to FIG. 34, in oneaspect, the signals from the upstream connector 230 may be taken to themodule printed circuit board through a flexible ribbon cable 310. Thesignals from the downstream connector 270 may be taken to the moduleprinted circuit board through a flexible ribbon cable 308. In oneaspect, the flexible ribbon cables 310, 308 may be flexible and lowprofile accommodating a limited space environment. The flexibility ofthe flexible ribbon cables 310, 308 may allow for any additional cablelength to be pushed aside in smaller sized modules. In one aspect,having additional cable length provides the needed cable length formodules of varying height.

In an alternative aspect, the module printed circuit board could be aflexible circuit with flexible cable coming off of it to attach to theupstream connector 230 and the downstream connector 270. For example,the upstream connector 230 would have flexible ribbon cable thatconnected to a flexible circuit board and the downstream connector 270would have flexible ribbon cable that connected to the flexible circuitboard. In one aspect, this aspect could reduce the number of electricalconnections needed between the backplane and the printed circuit board,which may have the potential to reduce any possible voltage drop in thesystem that could occur.

Mechanical Attachment of Backplane Connector of Back Panel

In one general aspect, the modular energy backplane connector may berigidly mounted so it can withstand abuse loads from misaligning moduleswhile stacking. In an alternate back plane connector subassembly theupstream and downstream connectors can be attached to part of the backpanel, which offers assembly benefits and eliminates the need to addadditional components for mechanical mounting of the upstream connector.

FIGS. 35 and 36 show different views of an alternate backplane connectorsubassembly 347 that is substantially similar to the back planeconnector subassemblies 343, 345. FIG. 35 shows an alternative upstreamconnector 211 that may be substantially similar to upstream connectors200, 230. For the sake of brevity, not all of the details that are thesame will be reiterated. In one aspect, upstream connector 211 maydiffer from the previous upstream connectors 200, 230 in how it attachesto the back panel 217. The back panel 217 may have two bent flanges 219located toward the middle of edge 209 of the back panel 217. Referringto FIG. 35, a cross-section of the back panel 217 is shown with thecross section location being at the bent flange 219. For example, thetwo bent flanges 219 are located such that each one may slide along aopposing side of the upstream connector 213 to place the upstreamconnector 213 in the middle of the back panel 217. The back panel 217may define a first vertical plane along the back panel. The bent flanges219 may move away from the first plane by a distance d3 and then turnvertical along a second vertical plane. The first vertical plane and thesecond vertical plane may be parallel to each other. Then the bentflange may turn at an angle perpendicular to the first plane and secondplane prior to reaching the edge 209, as shown in FIG. 35. The upstreamconnector 211 may slide onto the two bend flanges 219. For example, theupstream connector 211 may have 2 slots 231 on each side of the upstreamconnector 211, the two slots 231 may slide over the bend flanges 219.Each bent flange 219 may have a hole 233. In one aspect, when the bentflanges 219 slide into the slots 231 of the upstream connector theprotrusions 229 snap into the holes 233, which may attach the upstreamconnector 211 to the back panel 217. In one aspect, the hole 233 alsoaligns with a hole in the upstream connector 211. In one aspect, toremove the upstream connector 211 the protrusion 229 can be pressed downand out of the hole 231 so it can be slid off of the flange 219. Circle227 may highlight the area of FIG. 35 where the protrusion 229 snapsinto the hole 233.

Referring to FIG. 35, the upstream connector 211 may contain a housingand upper portion that extends vertically past the edge 209 similarly tothe upstream connectors 200, 230. The upstream connector 211 also maycontain a support rib or support ribs 225 that extend down to restagainst the back panel 217. The back panel 217 may contain holes 221that are located below the bent flanges 219. Upon attaching the upstreamconnector 211 to the back panel 217 the support ribs 225 may come downin line with the holes 221 such that a protrusion 223 on the support rib225 may enter the hole 221. In one aspect, the support ribs 225 restingagainst the back panel 217 and the protrusions 223 entering the holes221 may provide additional mechanical support. In one aspect, there canbe two support ribs 225 and two holes 221, one on each side of theupstream connector 211. In an alternate aspect, there could be anynumber of holes 221 and support ribs 225 that rest against them.

FIG. 36 shows an alternative downstream connector 243 that may besubstantially similar to downstream connectors 254, 270. For the sake ofbrevity, not all of the details that are the same will be reiterated. Inone aspect, downstream connector 243 may differ from the previousdownstream connectors 254, 270 in how it attaches to the back panel 217.The back panel 217 may have two bent flanges 237 and 235 located towardthe middle of edge of the back panel 217. Referring to FIG. 36, across-section of the back panel 217 is shown with the cross sectionlocation being at the bent flange 237. For example, the two bent flanges237, 235 are located such that each one may slide into a slot in thedownstream connector 243 to place the downstream connector 243 in themiddle of the back panel 217. For example the flange 237 may slide intoslot 249 of the downstream connector and on the opposite side of thedownstream connector the flange 235 may slide into a similar slot thatis not shown. The back panel 217 may then be attached to the bottom ofthe module enclosure 239 and a standoff 241 on the enclosure may slideinto a slot 251 that is located in both the flange 237 and downstreamconnector 243. In one aspect the slot 251 may only be located in thedownstream connector 243. On the opposing side of the downstreamconnector 243, there may be a similar standoff 241 that may slide into asecond slot located on the flange 235 and downstream connector 243. Inone aspect the second slot may only be located in the downstreamconnector 243. In one aspect, the standoffs 241 may allow the downstreamconnector to be located in the appropriate place in the bottomenclosure. Circle 247 may highlight the area of FIG. 36 where the flange241 slides into the slot 251.

Stacking modules using the back plane connector subassembly 347 issubstantially similar to the stacking of modules using the back planeconnector subassembly 343, 345. For the sake of brevity, not all of thedetails that are the same will be reiterated. When stacking a module,the upper portion 213 of the upstream connector 211 of the lower modulemay enter a cavity of the downstream connector 243 located in the uppermodule electrically and physically connecting the two modules. In oneaspect, a plug inside of the upstream connector 211 may connect with aplug inside of the downstream connector 243 to electrically connect themodules that are stacked. For example, when the modules are stacked theupper portion 213 may enter the cavity and a plug inside of thedownstream connector 243 may enter a hole in the upstream connector 211and connect with a plug inside of the upstream connector 211 toelectrically connect the modules. In one aspect, the plug may beintegrated into the connector assembly such that it is one moldedcomponent and not two separate components. In another aspect, the plugcould be a separate component inserted into the connector. In yetanother aspect, electrical pins/contacts may be integrated into theconnector, for example pressed into. In one aspect, electrical wires maycome down from a hole in the upstream connector 213, where theelectrical wires may start at the plug inside of the upstream connector211 and may terminate at a printed circuit board. In one aspect,electrical wires may come up from a hole 245 in the downstream connector243, where the electrical wires may start at the plug inside of thedownstream connector 243 and may terminate at a printed circuit board.Multiple modules can be stacked on top of one another no matter theheight the modules. Each module may have the same upstream connector 211and downstream connector 243, which allow the modules to be physicallyand electrically connected when the modules are stacked. When themodules are stacked and connected, power may transfer through theupstream connector 211 into the module and then through the downstreamconnector 243 to the next module lower in the stack. Electricalcommunications can pass through the upstream connector 211 anddownstream connector 243 both ways.

In various aspects, alternative methods of attaching an upstreamconnector and a downstream connector to a back panel are envisioned.Referring to FIG. 37A, flanges 261 could be attached to the back panel255 such that they may be aligned or offset from edge 253 of the backpanel 255. The flanges 261 may bend 257 away from the back panel 255 toprovide an area between them to slide an upstream connector ordownstream connector. The flanges 261 may comprise holes 259 where theupstream or downstream connector may have features that could snap intothe holes 259. Similar to the protrusion 229 of upstream connector 211.The upstream or downstream connector could be slid in direction 265until the bottom of the connector sat on the support ledges 267 and thenslid in direction 263 until the connector snapped into holes 259. In oneaspect, the flanges 261 could be attached to the back panel 255 bywelding. In an alternative aspect, the flanges 261 could be attached tothe back panel 255 by any means that would allow the mechanical supportneeded. In yet another aspect, the back panel 255 may require two setsof flanges 262 to be attached to allow one set to attach an upstreamconnector and one set to attach a downstream connector.

Referring to FIG. 37B, flanges 273 could be attached to the back panel269 such that they may be aligned or offset from an edge of the backpanel 269. The flanges 273 may be substantially similar to the flanges261. The flanges 273 may bend away from the back panel 269 to provide anarea between them to slide an upstream connector or downstreamconnector. The flanges 273 comprise holes 271 where the upstream ordownstream connector may have features that could snap into the holes271. Similar to the protrusion 229 of upstream connector 211. Theupstream or downstream connector could be slid in direction 275 untilthe bottom of the connector sat on the flanges 273 and then slid indirection 277 until a feature on the connector snapped into holes 271.In one aspect, the flanges 273 could be attached to the back panel 269by welding. In an alternative aspect, the flanges 273 could be attachedto the back panel 269 by any means that would provide the mechanicalsupport needed. In yet another aspect, the back panel 269 may requiretwo sets of flanges 271 to be attached to allow one set to attach anupstream connector and one set to attach a downstream connector. In yetanother aspect, the 2 types of flanges 273, 271 could be used togetherto attach an upstream connector and a downstream connector to a backpanel of a module.

Referring to FIG. 37C, a panel 281 could be attached to the back panel279 such that the panel 281 is in the middle of the back panel 279. Thepanel 281 may have flanges 285 located at the top of the panel 281. Theflanges 285 may comprise holes 287. An upstream connector may attach tothe flanges 287 in a manner similar to flanges 261 or flanges 271. Forexample, a upstream connector may slide onto the flanges 287 until afeature on the upstream connector snaps into the holes 287. The featurecould be similar to the protrusion 229 of upstream connector 211. Thepanel 281 may have flanges 289 located at the top of the panel 281. Theflanges 289 may comprise holes 291. An downstream connector may attachto the flanges 289 in a manner similar to flanges 261 or flanges 271.For example, a downstream connector may slide onto the flanges 289 untila feature on the downstream connector snaps into the holes 291. Thefeature could be similar to the protrusion 229 of upstream connector211. In one aspect, the panel 281 could be attached to the back panel279 by welding. In another aspect, the panel 281 could be attached tothe back panel 279 by fastener inserts 283. In yet another aspect, thepanel 281 could be attached to the back panel 279 by any means thatwould provide the mechanical support needed.

In various aspects, once the upstream and downstream connectors areattached to the back panel, the back panel connector subassembly maywork substantially similar to back panel connector subassemblies 343,345, 347. Stacking of modules may electrically and physically connectthe modules and the module height may vary between the modules beingstacked. In one aspect, the upstream and downstream connectors may beinterchanged between the backplane connector subassemblies and stillconnect properly. For example, a module with backplane connectorsubassembly 343 my connect with a module that has the backplaneconnector subassembly 345 or backplane connector subassembly 347. In analternative aspect, the modules may only connect with modules thatcontain the same backplane connector subassembly.

Using Enclosures to Fasten Backplane

In various general aspects, the backplane connector subassembly may beintegrated to the system in a robust mechanical manner with the abilityto withstand substantial mechanical forces pressing downward on theconnector. In one aspect, another consideration is to create a designthat does not add complexity of assembly or additional parts such asscrews etc. In yet another aspect, another consideration is to provide asolution that enables flexibility of attachment that accounts forvarying heights of modules.

In various general aspects, the modular energy system features abackplane connector subassembly that supplies communication and power tothe modules in the system. For example, one aspect for integrating thebackplane into mechanical architecture is to create a backplanesubassembly similar to a cartridge style design such it attaches to thelower enclosure. In one aspect, this could be implemented by attachingthe backplane subassembly on a framework shown in FIG. 38, or bysnapping features in the subassembly into tabs on the lower enclosureshown in FIG. 39.

In various general aspects, both aspects would enable ease andsimplicity of assembly by eliminating any additional assembly parts suchas screws etc. In various aspects, the backplane connector subassemblycartridge design would enable use of this design in a modular systemprovided modules were similar in height or that the cartridge heightcould be extended or reduced.

Referring to FIG. 38, a cartridge style back plane connector subassembly349 is shown. FIG. 38 illustrates 2 cartridge style back planeconnectors 354, 356. In one aspect, both cartridge style back planeconnectors 354, 356 may connect to the bottom 352 of the moduleenclosure. In back plane connector 354, a framework 360 may be attachedto the bottom 352 of the module enclosure. In one aspect, the cartridgestyle connector 358 of the back plane connector 354 is in one piece andslides on to the framework 360 to attach the cartridge style connector358 to the bottom 352 of the enclosure. When the cartridge style backplane connectors 354 is assembled and attached to the bottom 352 of thelower enclosure, then the top of the cartridge style connector 358 mayextend outside of the top of the module enclosure, not shown. Toaccommodate varying heights of modules, the height of the components inthe cartridge style backplane connector 354 may vary based on the heightof the module.

Still referring to FIG. 38, an alternate cartridge style backplaneconnector 356 is shown, where the backplane connector 356 is in multiplepieces. For example lower portion 364, middle portion 362, and upperportion 356. The lower portion 364 may connect to a framework on thebottom 352 of the enclosure. The middle portion 362 may attach to thelower portion as indicated by arrow 368. The upper portion may attach tothe lower portion as indicated by arrow 366. When the cartridge styleback plane connectors 356 is assembled and attached to the bottom 352 ofthe lower enclosure, then the upper portion 360 may extend outside ofthe top of the module enclosure, not shown. To accommodate varyingheights of modules, the height of the components in the cartridge stylebackplane connector 356 may vary based on the height of the module.

Modules using the cartridge style back plane connector subassembly 349can stack in a substantially similar manner to the back plane connectorsubassemblies 343, 345, 347. For example, the stacking of the moduleshas the top portion of the connector in the lower module enter the lowerportion of the connector in the upper module. Stacking of modules mayelectrically and physically connect the modules and the module heightmay vary between the modules being stacked.

Referring to FIG. 39, a cartridge style back plane connector subassembly351 is shown. The cartridge 372 of the cartridge style back planeconnector subassembly 351 may attach to the bottom 394 of the enclosure.In one aspect, the attachment may be made by snapping features 290 onthe cartridge 372 that snap into tabs 392 on the bottom 394 of theenclosure. The snapping features 290 are located at the bottom of frame378. The frame 378 may run the length of the cartridge 378 on eitherside of the cartridge 372. The bottom of the cartridge 378 may have afirst connector enclosure 386 that may extend into an enclosure 209 thatcan receive a connection from a cartridge of a lower module. The frame378 may contain protrusions 203 that can hold a printed circuit board201. A plug 388 may be connected to the first connector enclosure 386and electrical wires can extend from the plug 388 to the circuit board201. The electrical wires 380 extend away from the circuit board 201 andinto a plug located in the second connector enclosure 384. The hole 374in the second connector enclosure 380 allows a plug from a module higherin the stack to connect with the plug located in the second connectorenclosure 384 of the current module. The back panel 396 of the currentmodule may comprise vent holes 205 to allow air flow into the module.When the cartridge 372 is connected to the bottom 394 of the enclosure,the cartridge 372 extends vertically past the edge 398 of the back panelsuch that the upper portion 376 of the cartridge 372 extends outside ofthe module. To accommodate varying heights of modules, specificcartridges 273 of varying heights can be created to account for thevarying heights of the module.

Modules using the cartridge style back plane connector subassembly 351can stack in a substantially similar manner to the back plane connectorsubassemblies 343, 345, 347, 349. For example, the staking of themodules may have an upper portion 376 of the back plane connector in thelower module enter the lower portion of a back plane connector in theupper module. Stacking of modules may electrically and physicallyconnect the modules and the module height may vary between the modulesbeing stacked.

Using Crush Ribs to Capture Backplane Housing

In various general aspects, the modular energy system features abackplane that supplies communication and power to the modules in thesystem. In one aspect, the backplane may be integrated to the system ina robust mechanical manner with the ability to withstand substantialmechanical forces pressing downward on the connector. In another aspect,another consideration is to create a design that does not add complexityof assembly or additional parts such as screws etc. In yet anotheraspect, another consideration is to provide a solution that enablesflexibility of attachment that accounts for varying heights of modules.

One aspect for integrating the backplane connector into the mechanicalarchitecture may be to utilize the pre-existing interface of a crushrib. In various aspects, crush ribs are protruding features that areadded to an injection molding design to aid in the stability of apress-fit connection. These structures are used in holes or othercomponents into which another part may be press-fit. For plastic crushrib design, crush ribs may define either a pointed or rounded form. Inone aspect, crush ribs may be formed of a foam like material with hightolerances, and the thixoformed enclosure to sandwich the upstream anddownstream connectors between the crush ribs and enclosure. This processcould be implemented by adding crush ribs and guide bosses in the crushribs to secure and fix the backplane connector. This aspect wouldeliminate any complex assemble features or additional components forassembly purposes (such as screws, etc.), and allow for a similarimplementation among all modules in the system.

Referring to FIGS. 40 and 41, a back plane connector subassembly 353 isshown. In one aspect, the crush rib 312, which is a foam like materialwith high tolerances, sits inside of the back of the enclosure 318. Thecrush rib may be viewed as broke up into 3 sections a top crush rib 324,a middle crush rib 326, and a lower crush rib 328. The upstreamconnector 314 may be slid between the crush 312 and the top of theenclosure 318. The upstream connector 314 may be similar in many aspectsto upstream connectors 211, 230, 200. For the sake of brevity, not allof the details that are the same will be reiterated. The upstreamconnector 314 rests on top of the crushed ribs 330 of the crush rib 312.The upstream connector 314 may be placed on the crushed ribs 330 so thatthe alignment bosses 332 of the crush rib 312 enter into the guide holes334 on the upstream connector 314. FIG. 41 illustrates the bottom of theupstream connector 314. Referring primarily to FIG. 41, the guide holesmay be located on either side of the housing 348 of the upstreamconnector 314 and the indents 346 may be touch points for the crushedribs 330. A hole 320 may be the location where electrical component canpass information and power between the modules. For example, a plug thatmay be located inside of the hole 320, where the plug can connect theupstream connector with a downstream connector of another module thatmay be stacked on top of the current module.

Referring to FIG. 40, the downstream connector 316 may be slid betweenthe crush rib 312 and the bottom of the enclosure 318. The downstreamconnector 316 may be similar in many aspects to downstream connectors254, 270, 234. For the sake of brevity, not all of the details that arethe same will be reiterated. The downstream connector 316 may rest onthe bottom of the enclosure 318 with crushed ribs 342 of the crush rib312 holding the downstream connector 316 against the enclosure 318. Thedownstream connector 316 may be placed in the correct location bysliding the guide holes 344 on to the alignment bosses 340. Thedownstream connector may comprise a housing 350 that contains a cavity322 that is made to receive an upper portion 338 of an upstreamconnector during stacking of modules.

Modules using the back plane connector subassembly 353 can stack in asubstantially similar manner to the back plane connector subassemblies343, 345, 347, 349, 351. For example, when stacking a module, the upperportion 338 of the upstream connector 314 of the lower module may entera cavity 322 of the downstream connector 316 located in the upper moduleelectrically and physically connecting the two modules. In one aspect, aplug inside of the upstream connector 314 may connect with a plug insideof the downstream connector 316 to electrically connect the modules thatare stacked. For example, when the modules are stacked the upper portion338 may enter the cavity 322 and a plug inside of the downstreamconnector 316 may enter the hole 320 and connect with a plug inside ofthe upstream connector 338 to electrically connect the modules. In oneaspect, the plug may be integrated into the connector assembly such thatit is one molded component and not two separate components. In anotheraspect, the plug could be a separate component inserted into theconnector. In yet another aspect, electrical pins/contacts may beintegrated into the connector, for example pressed into. In one aspect,electrical wires may start at the plug inside of the upstream connector338 and terminate at a printed circuit board in the module. In oneaspect, similarly, electrical wires may start at the plug inside of thedownstream connector 316 and terminate at a printed circuit board in themodule. Multiple modules can be stacked on top of one another no matterthe height the modules. Each module may have the same upstream connector314 and downstream connector 316, which allow the modules to bephysically and electrically connected when the modules are stacked. Whenthe modules are stacked and connected, power may transfer through theupstream connector 338 into the module and then through the downstreamconnector 316 to the next module lower in the stack. Electricalcommunications can pass through the upstream connector 314 anddownstream connector 316 both ways.

Back Panel Support of Backplane

In various general aspects, the modular energy system backplane assemblyrequires a connector out both the top and bottom with a wire harness inthe middle. In one aspect, the design and assembly can be complicatedbased on the requirements.

In one aspect of a back plane subassembly, ribs may be added to the backpanel that stick out to support both the downstream and upstreamconnectors back plane subassembly. The bottom enclosure may be used tolocate the downstream connector and then the back panel may be placedover the top to secure the downstream connector in place. The upstreamconnector may be placed on the back panel ribs and then the wholeassembly could be sandwiched together by the top enclosure. In oneaspect, this process eliminates the need for screws into the twoenclosures and ensures a robust backplane connector with a simplisticdesign.

Referring to FIG. 42, a back plane connector subassembly 355 is shown.In one aspect, the upstream connector 293, support ribs 307 a, 307 b,and downstream connector 309 may be sandwiched together inside of theenclosure bottom 305 and enclosure top 303. The upstream connector 293and the downstream connector 309 may be similar to upstream connectors211, 230, 200, 314 and downstream connectors 254, 270, 234, 316. For thesake of brevity, not all of the details that are the same will bereiterated. The downstream connector 309 may comprise a housing 313 anda cavity 311 and the upstream connector 293 may comprise a housing 299,an upper portion 297, and a hole 295. The downstream connector 309 mayrest on the enclosure bottom 305. In one aspect, the downstreamconnector 309 may be placed so that protrusions 315 a, 315 b of theenclosure bottom 305 rest inside holes 321 a, 321 b of the downstreamconnector 309. Support ribs 307 a, 307 b may be attached to the backpanel 301. The back panel 301 may be placed against the enclosure bottom305 so that the support ribs 307 a, 307 b may rest on top of indents 317a, 317 b of the downstream connector 309. The upstream connector 293 mayrest on the support ribs 307 a, 307 b so that the support ribs 307 a,307 b rest inside of holes 319 a, 319 b of the upstream connector 293.The enclosure top 303 may rest against the upstream connector 293 tokeep the back plane connector subassembly 355 together. Varying heightsin modules may be accommodated by attaching support ribs 307 a, 307 bthat are an appropriate length to account for the height of the module.

Modules using the back plane connector subassembly 355 stack in asubstantially similar manner to the back plane connector subassemblies343, 345, 347, 349, 351, 353. For example, when stacking a module, theupper portion 297 of the upstream connector 293 of the lower module mayenter a cavity 311 of the downstream connector 309 located in the uppermodule electrically and physically connecting the two modules. In oneaspect, a plug inside of the upstream connector 293 may connect with aplug inside of the downstream connector 309 to electrically connect themodules that are stacked. For example, when the modules are stacked theupper portion 297 may enter the cavity 311 and a plug inside of thedownstream connector 309 may enter the hole 295 and connect with a pluginside of the upstream connector 293 to electrically connect themodules. In one aspect, the plug may be integrated into the connectorassembly such that it is one molded component and not two separatecomponents. In another aspect, the plug could be a separate componentinserted into the connector. In yet another aspect, electricalpins/contacts may be integrated into the connector, for example pressedinto. In one aspect, electrical wires may start at the plug inside ofthe upstream connector 293 and terminate at a printed circuit board inthe module. In one aspect, similarly, electrical wires may start at theplug inside of the downstream connector 309 and terminate at a printedcircuit board in the module. Multiple modules can be stacked on top ofone another no matter the height the modules. Each module may have thesame upstream connector 293 and downstream connector 309, which allowthe modules to be physically and electrically connected when the modulesare stacked. When the modules are stacked and connected, power maytransfer through the upstream connector 293 into the module and thenthrough the downstream connector 309 to the next module lower in thestack. Electrical communications can pass through the upstream connector293 and downstream connector 309 both ways.

Isolating Features in a Modular System

In various general aspects, in a modular capital system power may bedistributed through a common backplane interface. In the modular energysystem, the main power supply may be in the Header Module which candistribute 60V DC to downstream modules. This architecture may bedesigned to reduce the number of AC power cords in the OR. The systemmay be only as extensible as the AC power coming from the walls.External standards and known variation by country limit this toapproximately 12 A and approximately 1200 watts per power cord. Asolution may be needed to add additional power supplies while meetingexternal standards once 1200 watts is exceeded.

In one aspect, a module may be added to the stack of modules that cansupply additional power. For example a “power module” can be added tothe stack which has an additional 1200 W AC to DC power supply that canprovide back plane power. In one aspect, to add a power module to themodular energy system, its power domain may be required to be isolatedfrom the Header module's power domain as well as the domain of anyupstream modules. By having the largest possible power supply (1200 W)the power module may power itself, as well as other downstream modules.In one aspect, the power module could be a stand-alone module thatprovides power, or it could be a module that provides some otherclinical function as well, such as Visualization, SmokeEvac/Insufflation, Fluid Management, etc.

FIG. 43 illustrates a cross-section of a corner of a modular energysystem 357. The modular energy system 357 may comprise a header module323 that can provide power to any module below it in the module stack.For example, the header module 323 may provide power to a firstgenerator module 325 and a second generator module 327. The headermodule 323 may comprise a power cable 341 that may bring power to theheader module 323. The modular energy system 357 may also comprise apower module 329 that can provide power to any module below it in themodule stack. For example, the power module 329 may provide power to afuture module. In one aspect, the future module 331 could be anothergenerator module. In another aspect the future module could be any typeof module. The power module 329 may comprise a power cable 339 that maybring power to the power module 329. In one aspect, the power cable 339and the power cable 341 may be required to be connected to separatebranch circuits. All the modules in the modular energy system 357comprise rubber isolating feet at the bottom corners of the modules. Forexample, modules 323, 325, 327, 329, 331 in the modular energy system357 may have rubber isolating feet 333 a-e at the bottom corners of themodules. Modules that require power from an upstream module may havemetal grounding pads attached to the top corners. For example, themodules 325, 327, 331 may have metal grounding pads 335 a-c attached tothe top corners. In one aspect, the metal grounding pads make contactwith the module stacked above them so that the isolating feet do notmake contact. In one aspect, metallic grounding feet may not be presenton the top surface of the power module such that the rubber isolatingfeet 333 c of the module upstream of the power module make contact,which provides an isolation distance between the power domain of theheader module 323 and the power domain of the power module 329.

In the modular energy system 357 there may be multiple power domains.For example, the header module has a first power domain 337 and thepower module has a second power domain 359. The two power domains 337,359 may be isolated by the rubber isolating feet 333 c making contactthe with the last module in the first power domain 337 and the firstmodule in the second power domain 359. The last module in the firstpower domain 337 may be the second generator module 327 and the firstmodule in the second power domain 359 may be the power module 329.Modules that require power from an upstream module may have a metalgrounding pad attached to the top corners. The metal grounding pads mayrest against the modules above and below the grounding pad providing acommon ground between the modules in the power domain. In one aspect,the metal grounding pad of the module below may keep the rubberisolating feet of the module above from resting on the module below. Forexample, the metal grounding pads 335 b may lift the first generatormodule 325 so that the rubber isolating feet 333 b do not rest againstthe second generator module 327 and the first generator module 325 mayrests solely on the metal grounding pads 335 b.

In the modular energy system 357 power may flow through the power cords341, 339 to their respective power domains 337, 359. Power may flow intothe header module 323 and then may be provided down the stack to thefirst generator module 325 and the second generator module 327. Powerand communication electrical wires may begin at the header module 323and go into a downstream connector of the header module 325 that isconnected to an upstream connector of the first generator module 325.The power and communication electrical wires may then continue into thefirst generator module 325 from the upstream connector of the firstgenerator module 325. The power and communication electrical wires maythen continue from the first generator module 325 into a downstreamconnector of the first generator module 325 that is connected to anupstream connector of the second generator module 327. The power andcommunication electrical wires may then continue into the secondgenerator module 327 from the upstream connector of the second generatormodule 327. The power and communication electrical wires may thencontinue from the second generator module 327 into a downstreamconnector of the second generator module 327 that is connected to anupstream connector of the power module 329. The communication electricalwires may then continue from the upstream connector of the power module329 and into the power module 329. The upstream connector of the powermodule 329 may only contain communication electrical wires and no powerelectrical wires. Power electrical wires may enter the power module 329through the power cord 339. Power electrical wires may start at thepower module 329 and go to the downstream connector of the power module329. The communication electrical wires may continue from the powermodule 329 and go to the downstream connector of the power module 329.The downstream connector of the power module 329 may be connected to theupstream connector of the future module 331. The power and communicationelectrical wires may continue from the upstream connector of the futuremodule 331 into the future module 331. If more modules were connectedbelow the future module 331, then the power and communication electricalwires may continue in a similar manner to that described above.

The communication electrical wires connect all the modules in themodular energy system 357 and the communication electrical wires areisolated between the modules. The first and second generator modules325, 327 may be power by the header module 323 and have metal groundingpads 335 a, 335 b to maintain a common ground with the header module323. The future module 331 may be power by the power module 329 and mayhave metal grounding pads 335 c to maintain a common ground with thepower module 329. The power module 329 may not have a metal groundingpad and the rubber isolating feet 333 c make contact between the powermodule 329 and second generator module 327. The contact of the rubberisolating feet 333 c may provide an isolation distance between the firstpower domain 337 and the second power domain 359.

In this aspect modules are either independent or dependent. Independentmodules may have their own power supply and pass power through theirdownstream backplane connector. For example, the header module 323 andthe power module 329 may be independent modules. Independent modules maynot have power lines in their upstream connector. In one aspect, thepower passed through their downstream backplane connector may be 60V DC.In another aspect, the power passed through their downstream backplaneconnector may be any voltage of power not exceeding electricallimitations. Dependent modules may receive their power through themodules above it through the upstream backplane connector and may havethe ability to pass that power to the module below via the downstreambackplane connector. For example, the first generator module 325, thesecond generator module 327, and the future module 331 are dependentmodules.

EXAMPLES

Various aspects of modular energy systems comprising backplane connectorattachment mechanisms as described herein with reference to FIGS. 17-43are set out in the following numbered examples.

Example 1. A modular energy system that comprises a first module,comprising a first panel, and a first connector attached to the firstpanel. A portion of the first connector extends past a first edge of thefirst panel. The modular energy system further comprises a secondmodule, comprising a second panel, and a second connector attached tothe second panel. The second connector is aligned with a second edge ofthe second panel, and the second connector defines a cavity. The secondmodule is coupled to the first module, wherein the portion of the firstconnector that extends past the first edge of the first panel ispositioned within the cavity defined by the second connector.

Example 2. The modular energy system of Example 1, further comprising athird module, comprising a third panel and a third connector attached tothe third panel. The third connector is aligned with a third edge of thethird panel and the third connector defines a second cavity. The secondmodule further comprises a fourth connector attached to the secondpanel, wherein a portion of the fourth connector extends past a fourthedge of the second panel. The fourth edge of the second panel isopposite the second edge of the second panel. The third module iscoupled to the second module, wherein the portion of the fourthconnector that extends past the fourth edge of the second panel ispositioned within the second cavity of the third connector.

Example 3. The modular energy system of Example 2, wherein the first,second, and third modules can be different sizes.

Example 4. The modular energy system of any one or more of Examples 1through 3, wherein the first panel comprises a first support memberattached to and extending away from the first panel. The first connectorfurther defines a first hole in the first connector. The first connectoris slidably attachable to the panel, wherein the first support member isslidably receivable into the first hole defined by the first connector.

Example 5. The modular energy system of Example 4, wherein the firstpanel further comprises a support ledge attached to the panel, whereinthe support ledge is offset from the first support member. The firstconnector further comprises a support rib that extends away from thefirst connector, and wherein the support rib is configured to restagainst the support ledge in a configuration defined by the firstconnector attached to the first panel.

Example 6. The modular energy system of Example 4, wherein the firstpanel further comprises a second support member attached to andextending away from the first panel, wherein the second support memberis offset from the first support member. The second connector furtherdefines a second hole in the second connector. The second connector isslidably attachable to the first panel, wherein the second supportmember is slidably receivable into the second hole defined by the secondconnector.

Example 7. The modular energy system of any one or more of Examples 1through 6, wherein in the coupled configuration, the first module andthe second module are physically and electrically connected.

Example 8. The modular energy system of any one of Examples 4 through 7,wherein the first support member comprises a fastener insert.

Example 9. The modular energy system of Example 5, wherein the supportrib comprises multiple support ribs extending away from the firstconnector.

Example 10. A modular energy system, comprising a first module. Thefirst module comprises a first panel. The first panel comprises a firstsupport member attached to the panel, and a second support memberattached to the panel, wherein the second support member is offset fromthe first support member. The first panel further comprises a supportledge attached to the first panel, wherein the support ledge is locatedbetween the first support member and the second support member. Thefirst module further comprises a first connector, defining a first holein the first connector. The first connector comprises a support rib thatextends away from the first connector. The first connector is slidablyattachable to the first panel, wherein the first support member isslidably insertable into the first hole. In the attached configuration,the support rib is configured to rest against the support ledge. In theattached configuration, a portion of the first connector extends past afirst edge of the first panel. The first module further comprises asecond connector defining a cavity and a second hole. The secondconnector is slidably attachable to the first panel, wherein the secondsupport member is slidably receivable into the second hole. In theattached configuration the second connector is aligned with a secondedge of the first panel, wherein the second edge of the first panel isopposite the first edge of the first panel.

Example 11. The modular energy system of Example 10, further comprisinga second module. The second module comprises a second panel. The secondpanel comprises a third support member attached to the second panel, afourth support member attached to the second panel, wherein the fourthsupport member is offset from the third support member. The second panelfurther comprises a second support ledge attached to the second panel,wherein the support ledge is located between the third support memberand the fourth support member. The modular energy system furthercomprises a third connector defining a third hole in the thirdconnector. The third connector comprises a second support rib thatextends away from the third connector. The third connector is slidablyattachable to the second panel, wherein the third support member isslidably receivable into the third hole define by the third connector.In the attached configuration, the second support rib is configured torest against the second support ledge. In the attached configuration, asecond portion of the third connector extends past a third edge of thesecond panel. The modular energy system further comprises a fourthconnector defining a second cavity and a fourth hole in the fourthconnector. The fourth connector is slidably attachable to the secondpanel, wherein the fourth support member is slidably receivable into thefourth hole defined by the fourth connector. In the attachedconfiguration, the second connector is aligned with a fourth edge of thesecond panel, and wherein the third edge is opposite the fourth edge.

Example 12. The modular energy system of Example 11, wherein the firstmodule is coupled to the second module, and in the coupled configurationthe second portion of the third connector that extends past the secondpanel is positioned within the cavity defined by the second connector.

Example 13. The modular energy system of Example 11, wherein the secondmodule is coupled to the first module, and in the coupled configurationthe portion of the first connector that extends past the first panel ispositioned within the cavity defined by the fourth connector.

Example 14. The modular energy system of any one or more Examples 11through 13, wherein in the coupled configuration, the first module andthe second module are physically and electrically connected.

Example 15. A module for a modular energy system, the module comprises apanel. The panel comprises a first support member attached to andextending away from the panel, a second support member attached to andextending away from the panel, wherein the second support member isoffset from the first support member. The module further comprises afirst connector defining a first hole in the first connector. The firstconnector is slidably attachable to the panel, wherein the first supportmember is slidably receivable into the first hole. In the attachedconfiguration a portion of the first connector extends past a first edgeof the panel. The module further comprises a second connector defining acavity and a second hole. The second connector is slidably attachable tothe first panel, wherein the second support member is slidablyreceivable into the second hole. In the attached configuration thesecond connector is aligned with a second edge of the panel, and whereinthe second edge of the first panel is opposite the first edge of thepanel.

Example 16. The module of Example 15, wherein the panel furthercomprises a support ledge attached to the panel. The support ledge islocated between the first support member and the second support member.The first connector further comprises a support rib that extends awayfrom the first connector. In the attached configuration the support ribrests against the support ledge.

Example 17. The module of any one of Examples 15 through 16, wherein themodule is one of a plurality of modules and the plurality of modules arestackable by inserting the portion of a first connector that extendspast one module inside the cavity defined by a second connector ofanother module, wherein in the stacked configuration, the plurality ofmodules are physically and electrically connected.

Example 18. A modular energy system that comprises a header module,wherein the header module is configured to supply power to one or moreconnected dependent modules.

The modular energy system further comprises at least one dependentmodule connected to the header module and powered by the header module,and a power module connected to the dependent module, wherein the powermodule is configured to supply power to one or more other connecteddependent modules.

Example 19. The modular energy system of Example 18, wherein thedependent module comprises grounding feet at the top corners of thedependent module, and wherein the header module rests on the groundingfeet.

Example 20. The modular energy system of any one of Examples 18 through19, wherein the dependent module comprises isolating feet at the bottomcorners of the dependent module, wherein the isolating feet rest betweenthe dependent module and the power module, and wherein the isolatingfeet separate the dependent module from the power module.

Example 21. The modular energy system of any one or more of Examples 18through 20, wherein the header module and the dependent module are partof a first power domain and the power module is part of a second powerdomain, and wherein the first power domain is separate from the secondpower domain.

Bezel with Light Blocking Features for Modular Energy System

Having described a general implementation the header and modules ofmodular energy systems 2000, 3000, 6000, and various surgicalinstruments usable therewith, for example, surgical instruments 2204,2206, and 2208, the disclosure now turns to describe various aspects ofmodular energy systems comprising bezels with light blocking features.In other aspects, these other modular energy systems are substantiallysimilar to the modular energy system 2000, the modular energy system3000, and/or the modular energy system 6000 described hereinabove. Forthe sake of brevity, various details of the other modular energy systemsbeing described in the following sections, which are similar to themodular energy system 2000, the modular energy system 3000, and/or themodular energy system 6000, are not repeated herein. Any aspect of theother modular energy systems described below can be brought into themodular energy system 2000, the modular energy system 3000, or themodular energy system 6000.

As described hereinbelow with reference to FIGS. 44-65, in variousaspects, the present disclosure provides modular energy systems 2000,3000, 6000 comprising over-molded light pipes with mounting features. Inanother aspect, the present disclosure provides modular energy systems2000, 3000, 6000 comprising light blocking printed circuit board (PCB)inserts. In another aspect, the present disclosure provides modularenergy systems 2000, 3000, 6000 comprising angled vents for lightblocking. In yet another aspect, the present disclosure provides modularenergy systems 2000, 3000, 6000 comprising low pressure molded (LPM) ona PCB for light emitting diode (LED) light blocking.

Over-Molded Light Pipe with Mounting Features

As referenced elsewhere herein, modules of a modular energy system caninclude a number of different ports configured to deliver differentenergy modalities to corresponding surgical instruments that areconnected thereto. For example, the energy module 2004 can include aport assembly 2012 that includes a bipolar port 2014, a first monopolarport 2016 a, a second monopolar port 2016 b, a neutral electrode port2018 (to which a monopolar return pad is connectable), and a combinationenergy port 2020.

In one aspect, the ports 2012, 2014, 2016 a, 2016 b, 2018, 2020 can beconfigured to relay information to users. For example, any of the ports2012, 2014, 2016 a, 2016 b, 2018, 2020 can include light assemblies 2015that can be configured to relay information to the user regarding theport according to their color or state (e.g., flashing, solid,patterned, etc.). For example, a light assembly 2015 can change from afirst color to a second color when a plug is fully seated within therespective port. As another example, a light assembly 2015 can flash acolor, such as red, when a plug is improperly seated in the respectiveport. In one aspect, the color or state of the light assemblies 2015 canbe controlled by the header module 2002. For example, the header module2002 can cause the light assembly 2015 of each port to display a colorcorresponding to the color display for the port on the GUI 2008. Variousother aspects are envisioned where the ports can shine any number ofcolors for the purposes of conveying information to a user, such as whena port is available for use, when a port is not available for use, whenthere is a problem with a port, an energy level associated with a port,etc.

As the light generated by the energy module 2004 and the lightassemblies 2015 can provide a user with critical information regardingthe current state and functionality of the ports of the port assembly2012, it is important that light generated for a respective port is onlyvisible where intended. For example, it is important that light emittedto convey information for one port, such as the bipolar port 2014, isnot inadvertently shone through the energy module 2004 and seen at otherlocations of the energy module, such as at the monopolar port 2016 athat is adjacent to the bipolar port 2014. This inadvertent light couldconfuse a clinician as to what information the energy module is tryingto convey.

In various aspects, the light assemblies 2015 can comprise light pipes,which are materials that are meant to allow light to travel while beingdiffused, increase the apparent brightness of printed circuit board(PCB) mounted light emitting diodes (LEDs) within the module, while alsoproviding a more attractive user interface to the user. In one aspect,should a gap be defined between the light pipe and any of itssurrounding components, light could inadvertently shine to other areaswhere the light is not intended to shine, such as through the energymodule and out of another port. Therefore, a need exists to ensure thatlight is only shone to areas where intended. In addition, it isdesirable that the light pipe be able to be mounted to the enclosure ofthe energy module. Mounting the light pipe to the enclosure wouldprovide an ease in assembly of the port with the enclosure, whileallowing for quick replacement of the same should any component of theport need replaced.

Referring to FIG. 44, a port module 400 is provided, according to atleast one aspect of the present disclose. In one aspect, the port module400 can include a receptacle 402, a light pipe 404 surrounding thereceptacle 402, and mounting features 410 extending from the light pipe404. While the port module shown in FIG. 44 is intended for use as onetype of port module 400 (monopolar port module, bipolar port module,neutral electrode port module, combo energy port module, etc.), itshould be understood that the port modules can be sized and configuredfor use as other types of port modules, such as port module 401 shown inFIG. 45, that includes a different number of apertures to receive adifferent type of plug than port module 400.

In various aspects, the mounting features 410 can include a mounting arm412 and an aperture 414 defined in the mounting arm 412. As shown inFIGS. 50 and 51, as an example, the aperture 414 can be sized to receivea fastener 415, such as a screw, therethrough to mount the port module400 to an enclosure 406 of an energy module 408. In various aspects, asshown in FIG. 51, the port module 400 can be mounted to an inner face407 of the enclosure 406. Various other aspects are envisioned where theport module 400 can be mounted to a different part of the enclosure 406,such as to an outer face of the enclosure 406.

In various aspects, the mounting features 410 can further includealignment rails that can assist in properly aligning the apertures 414of the mounting features 410 with corresponding mounting holes 418defined in the enclosure 406, illustrated in FIG. 52, which are sized toreceive a fastener 415 for mounting the port module 400 to the enclosure406. In one aspect, the alignment rails can be received by a trackdefined by the enclosure 406 to guide the aperture 414 into operablealignment with the mounting hole 418 of the enclosure 406. The alignmentrails and the tracks can ensure that the port module 400 is properlyreceived and positioned in apertures 420 defined in the enclosure 406,as is shown in FIG. 52. In various aspects, the port module 400 canfurther include auxiliary alignments rails on other areas of the lightpipe 404 that do not include mounting features 410 to further assist inaligning the port module 400 with the corresponding aperture 420 definedin the enclosure 406. Similar to the alignment rails, the auxiliaryalignment rails can be received by a track to further assist in ensuringthat the port module 400 is properly received and positioned in theaperture 420 defined in the enclosure 406. In one aspect, the alignmentrails, the auxiliary alignment rails, and tracks can be defined toensure the front face of the port module 400 fits flush with theexternal face of the enclosure 406, thereby preventing the port module400 from “sticking out” past the front face of the enclosure 406. Invarious aspects, the mounting arms 412 can be received by a mountingboss within the enclosure 406. The mounting arms 412 can be positionedon the light pipe 404 such that they do not nominally touch off themounting boss of the enclosure 406, which can cause a forward bias,ensuring the alignment rails make contact with the inside surface of theenclosure 406.

As shown in FIG. 44, the port module 400 can include two mountingfeatures 410 extending from the light pipe 404 to allow the port module400 to be mounted to the enclosure 406 of the energy module 408. Themounting features 410 can extend from opposite corners of the portmodule 400 to provide for a secure connection of the port module 400 tothe enclosure 406. The use of at least two mounting features 410 canensure that the port module 400 does not rotate out of its intendedposition when mounted to the enclosure 406. While two mounting features410 are shown and described, any number of mounting features 410 can beutilized to couple the port module 400 to the enclosure 406. While themounting features 410 are shown extending from opposite corners of thelight pipe 404, the mounting features 410 can extend from any suitablelocation of the light pipe 404 to ensure that a secure connection ismade between the port module 400 to the enclosure 406 to maintain theport module 400 in the respective apertures 420. The mounting features410 can also be sized and positioned such that apertures 414 of themounting features 410 operably align with mounting holes 418 defined inthe enclosure 406 to ensure that the fastener 415 can extend throughboth the aperture 414 and the mounting hole 418 to properly mount theport module 400 to the enclosure 406. In one aspect, the apertures 414can comprise threads such that the aperture 414 can be threadablycoupled to the fastener 415 that also threadably couples to the mountinghole 418 of the enclosure 406.

In one aspect, light emitted from the light pipe 404 can be emittedlaterally therefrom and enter the mounting features 410, which can causethe occurrence of bright or dull spots in the port module 400. Invarious aspects, the mounting features 410 can extend from the lightpipe 404 such that a distance d_(f) is defined between the front faces438 of the mounting features 410 and the front face 439 of the lightpipe 404. The distance d_(f) can be selected in order to reduce theoccurrence of bright or dull spots, due to light emitted light pipe 404entering the areas of the mounting features 410. In various aspects, thecross sectional area at the interface between the mounting arms 412 ofthe mounting features 410 and light pipe 404 body can be reduced tofurther minimize light loss. In one aspect, the above-describedimprovements can reduce the occurrence of inconsistent output from thelight pipe 404. In various aspects, the mounting features 410 can becomprised a light diffusing material, such as an opaque plastic.

In various aspects, the enclosure 406 of the energy module 408 candefine predefined compartments 422, shown in FIGS. 51 and 52, that canreceive the port modules 400 therein. In one aspect, the mountingfeatures 410 can be sized such that the port modules 400 can fit withinpredefined compartments 422 defined within the enclosure 406 thatinclude the apertures 420. In various aspects, the enclosure 406 candefine a plurality of ribs 421 that can separate the predefinedcompartments 422 of the enclosure 406. The ribs 421 can be sized andpositioned to prevent compartment 422 to compartment 422 light bleeding,as will be discussed in more detail below, to ensure that light emittedwithin one compartment 422 for one port module 400 is not inadvertentlyseen in another compartment 422 that includes a second port module 400.While ribs 421 are shown as being defined by the enclosure 406 toseparate the predefined compartments 422, any number of ribs 421 can beutilized within other areas of the enclosure 406 to further inhibitlight travel within the enclosure 406. In various aspects, the ribs 421and the enclosure 406 can be of unitary construction. For example, theenclosure 406 and the ribs 421 can be formed together with an injectionmolding process. In various aspects, the ribs 421 can be separatecomponents that can be removably or permanently attached to enclosure406. For example, the ribs 421 could be part of a separate component ofthe system that are put in place during assembly of the enclosure 406.

In various aspects, referring to FIGS. 50-52, each compartment 422 ofthe enclosure 406 can define a chimney 419, which can serve as a lightguide to guide light emitted from the LEDs to icons that exist on theouter surface of the enclosure 406. The chimneys 419 can cause the iconsto illuminate to convey various states associated with for the portmodule 400 positioned in the compartment 422. In one aspect, thechimneys 419 can include a very shallow diffuse material and direct thelight towards the outer indicator for the purposes of conveyinginformation to a user of the system. In one aspect, the chimneys canblock light for a dedicated LED for the indicators

In various aspects, the enclosure 406 can define vent holes 423, asshown in FIGS. 51, 52, 53, and 54, that can function to vent out heatgenerated within the energy module 408. During use of the energy module408, light could bleed through the vent holes 423 and shine into otherareas of the operating room, thus confusing the clinician as to whatsignals are trying to be conveyed. In one aspect, the ribs 421 can bedefined within the enclosure 406 to prevent light generated within theenergy module 408 from bleeding out through the vent holes 423. Invarious other aspects, the vents 423 could be angled, such as is shownin FIG. 64 and will be described in more detail elsewhere herein, tofurther inhibit light escape from the energy module 408.

In one aspect, referring again to FIG. 44, the mounting features 410 canbe molded directly onto the light pipe 404. In various aspects, thelight pipe 404 and the mounting features 410 can be of unitaryconstruction. In various aspects, the light pipe 404 and the mountingfeatures 410 can be manufactured by a molding process, such as with aninjection molding process, as an example. Molding of the mountingfeatures 410 directly on the light pipe 404 can ensure accurateplacement of the port module 400 relative to the apertures 420 of theenclosure 406 as the port module 400 is mounted to the enclosure 406, aswell as ensures accurate placement of the light pipe 404 relative toLEDs within the energy module 408, as will be described in more detailbelow. In various other aspects, the light pipe 404 and the mountingfeatures 410 can be separately constructed and then coupled together,such as with a bonding agent. In various aspects, the mounting features410 can be removably coupleable to the light pipe 404 to allow forreplacement of the mounting features 410 should one break, as anexample.

In various aspects, referring now to FIG. 49, the energy module 408 caninclude a control circuit 430 that can be positioned within the energymodule 408 adjacent to the apertures 420 of the energy module 408. Thecontrol circuit 430 can define a plurality of apertures 432 that can besized and positioned along the control circuit 430 to align with theapertures 420 defined in the enclosure 406 such that the port modules400 can extend through both sets of apertures 420, 432. In variousaspects, the control circuit 430 can include a plurality of LEDspositioned thereon that face an inner wall 407 and the apertures 420.The plurality of LEDs can be grouped and positioned adjacent to theapertures 420 defined in the enclosure 406 such that, when informationis to be conveyed to a user, a specific grouping of LEDs of theplurality of LEDs can be illuminated and shine through the respectiveaperture 420. Example LEDs on a control circuit can be seen on FIG. 65.

In various aspects, the port modules 400 can comprise a port modulecircuit 434 that can electrically couple to the control circuit 430 whenthe port module 400 is coupled to the energy module 408. In one aspect,the control circuit 430 can transmit signals to the port module circuit434 when the port module 400 is coupled to the enclosure 406, as will bedescribed in more detail below, for the purposes of transmittingelectrical signals to electrosurgical instruments that are coupled tothe port module 400. In various aspects, referring to FIG. 44, the portmodules 400 can include a circuit holder 435 extending from thereceptacle 402, which can be sized to hold the port module circuit 434.

As referenced above, the port modules 400 can include a light pipe 404.The light pipes 404 can be optically coupled to respective LEDs on thecontrol circuit 430 such that that the light pipes 404 can transmitoptical, informational signals to a user of the energy module 408 fromthe LEDs. In one aspect, when the LEDs associated with one port module400 are illuminated, light emitting from the LED(s) can emit into andthrough the light pipe 404, providing an increase the apparentbrightness of the light emitted from the LED(s) and provide a user ofthe energy module 408 with a status of the port module 400 according tothe light that is emitted by the LEDs. In various aspects, the LEDs andlight pipe 404 can emit solid light, flashing light, patterned light, orany other type of light state, to indicate information to the user abouta status of the port module 400. Further, the LEDs and light pipe 404can emit any number of colors according to the status of the port module400, such as operational status, energy level status, etc. As oneexample, the LEDs and light pipe 404 can emit solid green light when theport module 400 is ready for use, emit flashing red light when the portmodule 400 is not ready for use, and emit patterned yellow light whenthe port module 400 is being prepared for use. Any number of color andlight states (solid, flashing, patterned, etc.) can be utilized toconvey information to a user.

As referenced above, referring again to FIG. 44, the port module 400 caninclude a receptacle 402. As shown in FIG. 44, the perimeter of thereceptacle 402 can be defined by the inner surface of the light pipe404. In various aspects, the receptacle 402 can be sized to receive aplug from a corresponding surgical instrument therein, such as is shownin FIG. 4, as an example. The receptacle 402 can include a back wall 424that defines apertures 426 therein and sidewalls 428 extending away fromthe back wall 424. The size of the receptacle 402, as well as the size,position, and number of apertures 426 defined in the back wall 424, canbe defined to correspond to an intended plug of a surgical instrument tobe used with the port module 400. For example, in one aspect, referringto FIG. 44, the back wall 424 can define three apertures correspondingto one type of plug. In another example aspect, referring to FIG. 45,the back wall 424 of a port module 401 can define four aperturescorresponding to a second type of plug.

In various aspects, referring now to FIG. 53, the port module circuit434 can be electrically coupled to pin receptacles 436 that are disposedwithin the apertures 426 of the back wall 424. The pin receptacles 436can be in electrical communication with the port module circuit 434 andcan be sized to receive pins from plugs of electrosurgical instrumentstherein. When the pins of the plugs are positioned in the pinreceptacles 436 and the port module circuit 434 is in electricalcommunication with the control circuit 430 of the energy module 408, thecontrol circuit 430 of the energy module 408 can transmit electricalsignals to the electrosurgical instrument.

In various aspects, the receptacle 402 can be molded directly withinlight pipe 404 to define a seal therebetween. In various aspects, thelight pipe 404 can be comprised of a first material and the receptacle402 can be comprised of a second material, where the first material hasa higher melting temperature than the first material. The light pipe 404can be injection molded with the first material to define the shape ofthe light pipe 404. Once the light pipe 404 has been formed, thereceptacle 402 can be injection molded with the second material withinthe formed light pipe 404 to define the back wall 424 and sidewalls 428.Once the second material has been injected into the light pipe 404, theapertures 426 can be defined in the back wall 424 according to theintended use of the port module 400. Injection molding the receptacle402 within the light pipe 404 allows for the creation of a sealtherebetween, which can prevent any inadvertent light from escapingbetween the light pipe 404 and the receptacle 402. This molding processcan also ensure a strong bond between the light pipe 404 and thereceptacle 402. The strong bond between the light pipe 404 and thereceptacle 402 is critical as the mounting features 410 on the lightpipe 404 are needed for mounting the port module 400 to the enclosure406, and therefore, the strong bond is critical to ensure accuratealignment of the port module 400 with the apertures 420 of the enclosure406.

As referenced above, a seal can be formed between the receptacle 402 andthe light pipe 404. The seal can ensure that light from the light pipe404 don't shine between the light pipe 404 and the receptacle 402, aswell as ensures that the port module 400 is properly mounted to theenclosure 406. In various aspects, the receptacle 402 can be comprisedof an opaque material. In one aspect, the opaque material can comprise aplastic opaque material. As referenced above, as a seal is definedbetween the light pipe 404 and the opaque receptacle 402, the opaquematerial can prevent light that is emitted from the LEDs and the lightpipe 404 from inadvertently escaping and shining into unintended areasof the energy module 408. As one example, the seal and opaque materialcan ensure that light emitted from one grouping of LEDs and a light pipe404 of one port module 400 is not mistakenly seen at another location ofthe energy module 408, such as at another port module 400.

In various aspects, referring now to FIGS. 47 and 48, the port module400 can further include engagement features that improve mechanicalstrength and engagement between the light pipe 404 and other componentsof the port module 400, such as the receptacle 402. In one aspect,engagement features can comprise engagement arms 440 defined in thelight pipe 404 that extend toward and be received in notches 442 definedin the receptacle 402. The engagement arms 440 can engage notches 442,which can improve the engagement between the light pipe 404 and thereceptacle 402. In various aspects, the engagement arms 440 and notches442 can be defined at any suitable location on the port module 400 toimprove the mechanical strength and engagement between the light pipe404 and other components of the port module 400, such as the receptacle402.

In various aspects, referring to FIG. 44, the light pipe 404 can definestops 416 that can define recesses to receive engagement members 417(see FIG. 48) extending from the receptacle 402 (note: FIG. 48illustrates a phantom view of the light pipe 404 such that the outersurface of the receptacle 402 and an engagement member 417 extendingtherefrom can be seen while the receptacle 402 is positioned in thelight pipe 404). In one aspect, the stops 416 and engagement members 417of the receptacle 402 can be utilized to align the light pipe 404 withthe receptacle 402. In one aspect, the engagement members 417 can bereceived in the stops 416 to create a flush relationship between thelight pipe 404 and the receptacle 402 through a positive stop.

Light Blocking PCB Inserts

As referenced elsewhere herein, modules of a modular energy system canutilize light for the purposes of conveying information to a user of themodular energy system. For example, ports 2012, 2014, 2016 a, 2016 b,2018, 2020 can be configured to relay information to users. For example,any of the ports 2012, 2014, 2016 a, 2016 b, 2018, 2020 can includelight assemblies 2015 that can be configured to relay information to theuser regarding the port according to their color or state (e.g.,flashing, solid, patterned, etc.). For example, a light assembly 2015can change from a first color to a second color when a plug is fullyseated within the respective port. As another example, a light assembly2015 can flash a color, such as red, when a plug is improperly seated inthe respective port. In one aspect, the color or state of the lightassemblies 2015 can be controlled by the header module 2002. Forexample, the header module 2002 can cause the light assembly 2015 ofeach port to display a color corresponding to the color display for theport on the GUI 2008. Various other aspects are envisioned where theports can shine any number of colors for the purposes of conveyinginformation to a user, such as when a port is available for use, when aport is not available for use, when there is a problem with a port, anenergy level of a port, etc.

As the light generated by the modules provides a user with criticalinformation regarding the current state of the module, it is importantthat light generated by the module is only visible where intended. Asdescribed elsewhere herein, the modules can include an enclosure, suchas enclosure 406, that houses the components of the module therein. Invarious aspect, the enclosure can include apertures, such as apertures420, defined therein that are sized to receive port modules, such asport modules 400, therein. The enclosure can further include a controlcircuit, such as control circuit 430, that can control various functionsof the module, such as controlling LEDs thereon that are emitted toconvey information to the user regarding the status of the port modules400, as well as controlling an amount or type of energy that isdelivered to an electrosurgical instrument that is coupled to the portmodule. The control circuit can also include apertures, such asapertures 432, that can be sized and positioned adjacent to apertures ofthe enclosure such that the port modules can extend through both theapertures of the enclosure and the apertures of the control circuit whenthe port module is coupled to the energy module. In various aspects, asreferenced above, the control circuit can further include LEDs that aremounted to the control circuit. The LEDs can be positioned on thecontrol circuit such that light emitted from the LEDs can emit towardthe aperture of the enclosure, thus conveying information to the userabout the status of the port modules.

Referring now to FIG. 58, when port modules 450, which can be similar toport modules 400, extend through apertures defined in the enclosure 451and apertures 452 defined in the control circuit 454, a gap 456 can bedefined between the inner perimeter of the aperture 452 and the portmodule 450. As a result of the gap 456, light emitted from the LEDs onthe control circuit 454 can escape through the gap 456 and emit intoother areas of the enclosure 451. In some scenarios, the escaped lightcould enter another aperture 452 defined in the control circuit, causingthe light corresponding to one port module 450 to inadvertently beenseen at different port module 450 location. As a result, a user could beconfused as to which port module 450 is being illuminated and whatinformation is being conveyed by the module. In other instances, theescaped light could also escape the enclosure 451 through the vents 458defined in the sides of the enclosure 451 and be seen at other locationsof the operating room. Accordingly, a need exists to block reward lighttravel through the gap 456 to prevent inadvertent light visibility atother locations of the enclosure 451 and the operating room.

Referring now to FIG. 55, a light blocking insert 460 is provided,according to at least one aspect of the present disclosure. The lightblocking insert 460 can include a face 462, guidewalls 464 extendingfrom the face 462, and mounting features 466 extending from the face462. Referring to FIGS. 56 and 57, the face 462 of the light blockinginsert 460 can be defined such that, when the light blocking insert 460is inserted into the aperture 452 of the control circuit 454, as will bediscussed in more detail below, the face 462 can seal the gap 456 toprevent light from escaping through the gap 456 to other areas of theenclosure 451.

As referenced above, the light blocking insert 460 can include aplurality of mounting features 466. The mounting features 466 can bemovable relative to the guidewalls 464 between a resting position (seenin FIG. 55) and a depressed position. In various aspects, the mountingfeatures 466 can be biased toward the resting position. While sixmounting features are shown in FIG. 55, any more of less mountingfeatures 466 can be utilized.

In various aspects, the mounting features 466 can include a base 468extending from the face 462, a lip 470 extending from the base 468, andan actuator portion 472 extending from the base 468. In various aspects,the lip 470 can extend transversely relative to the base 468 and theactuator portion 472. In various aspects, the light blocking insert 460can be removably coupled to the control circuit 454 to cover the gap456. In operation, the guidewalls 464 and the mounting features 466 canbe inserted through the aperture 452 of the control circuit 454 andtoward the aperture of the enclosure 451. As the light blocking insert460 moves through the aperture 452 of the control circuit 454, the lips470 of the mounting features 466 can engage the inner perimeter of theaperture 452. The aperture 452 can force the mounting features 466 torotate toward the depressed positions, allowing the lips 470 to passfrom a first side of the control circuit 454, through the aperture 452,and to a second side of the control circuit 454. Once the lips 470 movebeyond the aperture 452, the mounting features 466 can be snap back tothe resting position, where the bases 468 and the lips 470 of themounting features 466 can engage the control circuit 454, maintainingthe position of the light blocking insert 460 relative to the controlcircuit 454, such as is shown in FIGS. 56 and 57. In one aspect, whilethe mounting features 466 are moving toward and through the apertures452, the guidewalls 464 can assist in guiding the mounting features 466into operable alignment with the inner perimeter of the apertures 452.

With the mounting features 466 operably engaged with the control circuit454, a user can remove the light blocking insert 460 from the controlcircuit 454. In one aspect, the light blocking insert 460 can be removedby pushing the mounting features 466 toward the depressed position,thereby releasing the lip 470 and the base 468 from the control circuit454. As referenced above, the mounting features 466 can include anactuator portion 472 extending from the base 468. In operation, a usercan move the mounting features 466 toward the depressed position bypressing on the actuator portions 472 with, for example, their finger,to release the lip 470 and the base 468 from the control circuit 454,thereby allowing the light blocking insert 460 to be removed from theaperture 452. In various aspects, the actuator portion 472 can includegrips defined therein to assist a user with moving the mounting features466 toward the depressed position.

In various aspects, the light blocking insert 460 can be comprised of aplastic material and can be manufactured with a molding process. In oneaspect, the molding process can be an injection molding process. Invarious aspects, the light blocking insert 460 can be manufactured usingany other suitable manufacturing process, such as an additivemanufacturing process, a 3D printing process, etc. In various aspects,the light blocking insert 460 can be comprised of an opaque plasticmaterial. In various aspects, the light blocking insert 460 can becomprised of an opaque elastomeric material.

Angled Vents for Light Blocking

As referenced elsewhere herein, modules of a modular energy system canutilize light for the purposes of conveying information to a user of themodular energy system. For example, ports 2012, 2014, 2016 a, 2016 b,2018, 2020 can be configured to relay information to users. For example,any of the ports 2012, 2014, 2016 a, 2016 b, 2018, 2020 can includelight assemblies 2015 that can be configured to relay information to theuser regarding the port according to their color or state (e.g.,flashing, solid, patterned, etc.). For example, a light assembly 2015can change from a first color to a second color when a plug is fullyseated within the respective port. As another example, a light assembly2015 can flash a color, such as red, when a plug is improperly seated inthe respective port. In one aspect, the color or state of the lightassemblies 2015 can be controlled by the header module 2002. Forexample, the header module 2002 can cause the light assembly 2015 ofeach port to display a color corresponding to the color display for theport on the GUI 2008. Various other aspects are envisioned where theports can shine any number of colors for the purposes of conveyinginformation to a user, such as when a port is available for use, when aport is not available for use, when there is a problem with a port, anenergy level of a port, etc.

As the light generated by the modules provides a user with criticalinformation regarding the current state of the module, it is importantthat light generated within the module only be visible where intended.In various aspects, modules can include an enclosure, such as enclosure406, that houses the components of the module therein. In some aspects,the enclosure can include vents, such as vents 423, 458, defined thereinfor the purposes of venting heat out of the module to prevent the modulefrom overheating. These vents, however, can allow for unintended escapeof light generated within the module. This escaped light may shine ontoother areas within the operating room that also rely on light for thepurposes of indication. This overlap of light patterns may cause theclinician to become confused as what information is intended to beconveyed. Therefore, it is desirable to ensure that light generated by amodule is not visible outside of the enclosure, such as through thevents, except for where intended.

Referring now to FIG. 59, a module 500 is provided according to at leastone aspect of the present disclosure. The module can be any suitablemodule for use with a modular energy system, such as a header module2002, an energy module 2004, a technology module 2040, a visualizationmodule 2042, or any suitable module for use with a modular energysystem. In one aspect, the module can be an energy module that includesa port assembly 502, which can be similar to port assembly 2012.

In one aspect, the module 500 can include an enclosure 504 that housescomponents of the module therein. The enclosure 504 can include aplurality of faces, such as a front face 506, a back face 508, a pair ofsidewalls 510, a top face 512, and a bottom face 514. As shown in FIG.59, the enclosure 504 of the module 500 can define vents 516, or holes,in the sidewalls 510 that can vent heat generated by the module 500 toprevent the module 500 from overheating. While vents 516 are shown anddescribed are being defined in the sidewalls 510 of the enclosure 504,it should be understood that vents 516 can be defined in any suitablelocation on the enclosure 504, such as any other of the faces 506, 508,512, 514 of the enclosure 504 for the purposes of venting heat generatedby the module 500. In various aspects, the enclosure 504 can be definedwith an injection molding process and the vents 516 can be drafted.

In one aspect, as shown most clearly in FIG. 64, the enclosure 504 candefine vents 516 that can be angled relative to a sidewall plane definedby the sidewall 510 of the enclosure 504, which can hinder light escapefrom the enclosure 504. In various aspects, the vents 516 can include avent inlet 518, a vent outlet 520, and a track 522 extending from thevent inlet 518 to the vent outlet 520. In one aspect, the tracks 522 canbe angled θ relative to the sidewall plane at any suitable angle toinhibit light from escaping the enclosure 504. In one aspect, as isshown in FIG. 64, the vent inlets 518 and vent outlets 520 can bevertically offset such that the track 522 defines a non-perpendicularlyangle θ relative to the sidewall plane. In one aspect, the vent inlets518 and vent outlets 520 can be vertically offset such that the angle θof the track 522 is 45° relative to the sidewall plane. In otheraspects, the vent inlets 518 and vent outlets 520 can be offset suchthat the angle θ of the tracks 522 are greater than 45° relative to thesidewall plane, such as 50°, 55°, 60°, 70°, or any other suitable angle.In other aspects, the vent inlets 518 and vent outlets 520 can be offsetsuch that the angle θ of the track 522 is less than 45° relative to thesidewall plane, such as 40°, 35°, 30°, 20°, or any other suitable angle.In various aspects, some vents 516 can include an angle θ that differsfrom other vents. Stated another way, the enclosure 504 can includenon-uniformly angled vents 516 angled relative to the sidewall plane.

In one aspect, as is shown in FIG. 64, the enclosure 504 can definevents 516 that can be angled “downward”, where the vent outlets 520 canbe positioned vertically below the vent inlets 518, closer to the bottomface 514 of the enclosure. In various other aspects, the enclosure 504can define vents 516 that can be angled “upward”, where the vent outlets520 can be positioned vertically above the vent inlets 518, closer tothe top face 512 of the enclosure. In various other aspects, theenclosure 504 can include a combination of upward angled vents 516 anddownward angled vents 516. In various aspects, the enclosure 504 candefine vents 516 that are angled in other directions, such as forwardangled or backward angled. For example, in various aspects, theenclosure 504 can define vents 516 that can be angled “forward”, wherethe vent outlets 520 can be positioned closer to the front face 506 thanthe vent inlets 518. In various aspects, the enclosure 504 can definevents 516 that can be angled “backward”, where the vent outlets 520 canbe positioned closer to the back face 508 than the vent inlets 518. Invarious aspects, the enclosure 504 can define vents 516 that can beangled in more than one direction. For example, in one example aspect,the enclosure 504 can define vents 516 where the vent outlets 520 can bepositioned closer to the front face 506 and the top face 512 whencompared to the vent inlets 518. The use of angled vents can provide asimilar, or improved, airflow compared to non-angled vents, as well ascan provide the added benefit of preventing light from escaping themodule. In various aspects, the enclosure 504 can define vents 516 thatcan be angled in a plurality of non-uniform directions.

As referenced above, the vents 516 can include a vent inlet 518, a ventoutlet 520, and a track 522 extending from the vent inlet 518 to thevent outlet 520. In various aspects, the tracks 522 can be linear, asshown in FIG. 64. In various aspects, the tracks 522 can be non-linear(i.e., the tracks 522 non-linearly extend from the vent inlet 518 to thevent outlet 520). In various aspects, the track 522 can include a firsttrack portion extending from the vent inlet 518 and a second trackportion angled relative to the first track portion, extending from thefirst track portion and to the vent outlet 520. The use of multiple,angled track portions between the vent inlet 518 and vent outlet 520 canfurther prevent light from escaping the enclosure 504.

LPM on a PCB for LED Light Blocking

As referenced elsewhere herein, modules of a modular energy system canutilize light for the purposes of conveying information to a user of themodular energy system. For example, ports 2012, 2014, 2016 a, 2016 b,2018, 2020 can be configured to relay information to users. For example,any of the ports 2012, 2014, 2016 a, 2016 b, 2018, 2020 can includelight assemblies 2015 that can be configured to relay information to theuser regarding the port according to their color or state (e.g.,flashing, solid, patterned, etc.). For example, a light assembly 2015can change from a first color to a second color when a plug is fullyseated within the respective port. As another example, a light assembly2015 can flash a color, such as red, when a plug is improperly seated inthe respective port. In one aspect, the color or state of the lightassemblies 2015 can be controlled by the header module 2002. Forexample, the header module 2002 can cause the light assembly 2015 ofeach port to display a color corresponding to the color display for theport on the GUI 2008. Various other aspects are envisioned where theports can shine any number of colors for the purposes of conveyinginformation to a user, such as when a port is available for use, when aport is not available for use, when there is a problem with a port, anenergy level of a port, etc.

As the light generated by the modules provides a user with criticalinformation regarding the current state of the module, it is importantthat light generated within the module only be visible where intended.As referenced elsewhere herein, the modules can include an enclosure anda control circuit positioned therein. In one aspect, the control circuitcan include a plurality of LEDs positioned thereon that face an innerwall of the enclosure and apertures defined in the enclosure. Theplurality of LEDs can be grouped and positioned adjacent to theapertures defined in the enclosure such that, when information is to beconveyed to a user, a specific grouping of LEDs of the plurality of LEDscan be illuminated and shine through the respective aperture. This lightcan convey information associated with a port module that is positionedwithin the respective aperture, signifying a state of the port module(ready for use, not ready for use, an energy level associated with theport module, etc.).

As the plurality of LEDs can be grouped and positioned adjacent to aplurality of apertures defined in the enclosure, there is a chance thatlight generated by a first grouping of LEDs may be seen through not onlythe respective aperture associated with the first grouping of LEDs, butalso another aperture that may be in close proximity to the firstgrouping of LEDs. For example, when light is emitted from LEDs, a userhas no control over what direction the light emitted from the LEDs goes,which can result in light being seen at other locations within themodule other than where intended, such as through other aperturesdefined in the enclosure. This inadvertent light shone through theunintended apertures may confuse the clinician as to what informationthe LEDs are intending to convey to the clinician. A need exists toensure that this inadvertent light shining is eliminated.

Referring now to FIG. 65, a control circuit 550 is provided, accordingto at least one aspect of the present disclosure. In various aspects,the control circuit 550 can include an aperture 552 defined therein thatis sized to receive a port module, such as port modules 400, 401, 450therein. In one aspect, the aperture 552 can be similar to apertures432, 452. In various aspects, the control circuit 550 can furtherinclude a plurality of LEDs 554 surrounding the aperture 552. The LEDs554 can be mounted to the control circuit 550 and can be in electricalcommunication therewith such that the control circuit 550 can controllight that can be emitted by the LEDs. In one aspect, the controlcircuit 550 can control the LEDs 554 to cause the LEDs 554 to emit lightaccording to a current status of a port module that is positioned withinthe aperture 552.

In various aspects, the control circuit 550 can further include acontainment structure 560 including a plurality of sidewalls 562extending from the control circuit 550. The containment structure 560can be positioned on the control circuit 550 such that the sidewalls 562encompass and surround the aperture 552 and the plurality of LEDs 554.In various aspects, the sidewalls 562 can extend a height from a surfaceof the control circuit 550 such that the height of the sidewalls 562 isgreater than or equal to the height of the LEDs. As shown in FIG. 65,the containment structure 560 can define a rectangular-like shape tosurround the LEDs 554 and the aperture 552. In various other aspects,the containment structure 560 can define any suitable shape such thatthe containment structure 560 surrounds the LEDs 564 and the aperture552, such as a circular shape, a square shape, etc.

In one aspect, the containment structure 560 can be LPM directed ontothe surface of the control circuit 550. Various other aspects areenvisioned where the containment structure 560 is made separate from thecontrol circuit 550 and removably coupled thereto with a bonding agent.In one aspect, the containment structure 560 can be comprised of anopaque material. In various aspects, the containment structure 560 canbe comprised of an opaque plastic material. In various aspects, thecontainment structure 560 can be comprised of an opaque elastomermaterial. In one aspect, the use of the containment structure 560 canprevent light emitted from the LEDs 556 from traveling laterally alongthe control circuit 550; rather, the containment structure 560 candirect light emitted from the LEDs 556 toward the apertures defined inthe enclosure of the module. In various aspects, the containmentstructure 560 can direct light emitted from the LEDs 556 toward lightpipes of the port modules positioned in the aperture 552 of the controlcircuit 550.

In one aspect, the sidewalls 562 can be of uniform thickness. In variousother aspects, the sidewalls 562 can have varying thicknesses. Forexample, in one aspect, sidewalls 562 that are positioned between othergroupings of LEDs on the control circuit 550 can be thicker thansidewalls 562 that are not separating groups of LEDs on the controlcircuit. In various aspects, the sidewalls can be of non-uniformheights. In various aspects, the sidewalls can be of uniform heights. Inone aspect, the sidewalls 562 of the containment structure 560 can bepositioned close to the LEDs 556, as shown in FIG. 65, such that lightemitted by the LEDs 556 can be stopped and redirected toward theapertures of the enclosure as soon as possible from the light beingemitted by the LEDs 556.

It should be understood that various aspects of the disclosure describedherein, such as the disclosure associated with FIGS. 44-65, as anexample, may be utilized independently, or in combination, with oneanother.

EXAMPLES

Various aspects of modular energy systems comprising bezels with lightblocking features as described herein with reference to FIGS. 44-65 areset out in the following numbered examples.

Example 1. A port module removably coupleable to an energy module of amodule energy system, wherein the port module comprises a light pipe anda receptacle defined by the light pipe, wherein the receptacle isconfigured to receive a plug of an electrosurgical instrument therein,and wherein a seal is defined between the light pipe and the receptacle.

Example 2. The port module of Example 1, further comprising a mountingfeature extending from the light pipe, wherein the energy modulecomprises an enclosure, and wherein the mounting feature is configuredto mount to the enclosure.

Example 3. The port module of Example 2, wherein the mounting featurecomprises a mounting arm and an aperture defined in the mounting arm.

Example 4. The port module of any or more of Examples 2 through 3, wherea distance is defined between a front face of the light pipe and a frontface of the mounting feature, and where the distance is selected toreduce occurrence of bright or dull spots of light emitted from thelight pipe.

Example 5. The port module of any one or more of Examples 1 through 4,wherein the light pipe comprises an engagement arm, wherein thereceptacle defines a notch, and where the engagement arm is receivedwithin the notch.

Example 6. The port module of any one or more of Examples 1 through 5,wherein the receptacle comprises a back wall defining apertures, whereinthe plug of the electrosurgical instrument comprises pins, and whereinthe apertures are configured to receive the pins of the plug.

Example 7. The port module of any one or more of Examples 5 through 6,wherein the receptacle further comprises sidewalls extending from theback wall, and wherein the back wall and the sidewalls are comprised ofan opaque material.

Example 8. An energy module of a module energy system, wherein theenergy module comprises an enclosure defining a first aperture, acontrol circuit positioned within the enclosure, a port module, and alight blocking insert. The control circuit defines a second aperturealigned with the first aperture. The port module extends through thefirst aperture and the second aperture. A gap is defined between thesecond aperture and the port module. The light blocking insert ispositioned in the gap.

Example 9. The energy module of Example 8, wherein the light blockinginsert is configured to removably couple to the control circuit.

Example 10. The energy module of Example 9, wherein the light blockinginsert comprises a plurality of mounting features, and wherein theplurality of mounting features are configured to removably couple thelight blocking insert to the control circuit.

Example 11. The energy module of Example 10, wherein the mountingfeatures comprise a lip configured to engage the control circuit toremovably couple the light blocking insert to the control circuit.

Example 12. The energy module of any one or more of Examples 8 through11, wherein the control circuit comprises an LED, and wherein the lightblocking insert is configured to prevent light emitted from the LED fromescaping through the gap.

Example 13. The energy module of Example 12, wherein the control circuitfurther comprises sidewalls surrounding the LED, wherein the sidewallsare configured to direct light emitted from the LED toward the firstaperture.

Example 14. The energy module of Example 13, wherein the sidewalls areconfigured to prevent light emitted from the LED from escaping throughthe sidewalls.

Example 15. The energy module of any one or more of Examples 13 through14, wherein the sidewalls are comprised of an opaque material.

Example 16. The energy module of any one or more of Examples 8 through15, further comprising a vent, comprising a vent inlet, a vent outlet,and a track angularly extending from the vent inlet to the vent outlet.

Example 17. An energy module of a module energy system, wherein theenergy module comprises an enclosure defining a first aperture, acontrol circuit positioned within the enclosure, a port module, and alight blocking insert. The control circuit defines a second aperturealigned with the first aperture. The port module extends through thefirst aperture and the second aperture. The port module comprises alight pipe and a receptacle, wherein the receptacle is configured toreceive a plug of an electrosurgical instrument therein, wherein a sealis defined between the light pipe and the receptacle, and wherein a gapis defined between the second aperture and the port module. The lightblocking insert is positioned in the gap.

Example 18. The energy module of Example 17, wherein the receptacle iscomprised of an opaque material.

Example 19. The energy module of any one or more of Examples 17 through18, wherein the port module is configured to removably couple to theenclosure.

Example 20. The energy module of any one or more of Examples 17 through19, wherein the light blocking insert is configured to removably coupleto the control circuit.

Header for Modular Energy System

Having described a general implementation the header and modules ofmodular energy systems 2000, 3000, 6000, and various surgicalinstruments usable therewith, for example, surgical instruments 2204,2206, and 2208, the disclosure now turns to describe various aspects ofmodular energy systems comprising a header. In other aspects, thesemodular energy systems are substantially similar to the modular energysystem 2000, the modular energy system 3000, and/or the modular energysystem 6000. For the sake of brevity, various details of the othermodular energy systems being described in the following sections, whichare similar to the modular energy system 2000, the modular energy system3000, and/or the modular energy system 6000, are not repeated herein.Any aspect of the other modular energy systems described below can bebrought into the modular energy system 2000, the modular energy system3000, or the modular energy system 6000.

As described hereinbelow with reference to FIGS. 66-97, in variousaspects the present disclosure provides screen connection methods formodular energy systems 2000, 3000, 6000. In one aspect, the presentdisclosure provides modular energy systems 2000, 3000, 6000 comprisingaccessible memory. In another aspect, the present disclosure providesmodular energy systems 2000, 3000, 6000 comprising printed circuitmounted (PCB) mounted connector biasing with crush ribs. In yet anotheraspect, the present disclosure provides modular energy systems 2000,3000, 6000 comprising screen construction on capital systems.

Screen Connection Method

As referenced elsewhere herein, operating rooms (ORs) everywhere in theworld are a tangled web of cords, devices, and people due to the amountof equipment required to perform surgical procedures. Surgical capitalequipment tends to be a major contributor to this issue. For instance,as additional advanced equipment is needed for individual procedures,ORs continue to become more cramped. This problem can be addressedutilizing a modular energy system.

For example, a modular energy system, such as modular energy system2000, can be assembled from a variety of different modules that canprovide different functionality, thereby allowing the modular energysystem to be assembled into different configurations to customize thefunctions and capabilities of the modular energy system by customizingthe modules that are included in each modular energy system. Forexample, as discussed above, the modular energy system could includesome combination of a header module, such as header module 2002 (whichcan include a display screen, such as display screen 2006), an energymodule, such as energy module 2004, a technology module, such astechnology module 2040, and/or a visualization module, such asvisualization module 2042.

In various aspects, the header module of the modular energy system canbe configured to control the system-wide settings of each module andcomponent connected thereto in the modular energy system throughphysical controls, such as physical controls 2011 thereon and/or agraphical user interface (GUI), such as GUI 2008, rendered on thedisplay screen. Such settings could include the activation of themodular energy system, the volume of alerts, footswitch settings,settings icons, appearance or configuration of the user interface, thesurgeon profile logged into the modular energy system, and/or the typeof surgical procedure being performed. The header module can also beconfigured to provide communications, processing, and/or power for themodules that are connected to the header module.

Currently, there is a trend towards touchscreen displays on equipmentbecause it both provides increased functionality and flexibility overknobs or buttons. However, it is ideal that these displays be as largeas possible to ease the use on an operator of the display since smalltext and touch areas can be difficult to use. Therefore, there is a needto minimize the size of equipment, while also maximizing the size of thedisplay.

Referring now to FIGS. 66 and 67, a modular energy system 600 isprovided, according to at least one aspect of the present disclosure.The modular energy system 600 can include a header module 602, which canbe similar to header module 2002, and an energy module 604, such can besimilar to energy module 2004. While the modular energy system 600 asshown and described includes a header module 602 and an energy module604, it should be understood that the modular energy system 600 couldinclude any number or combination of modules, such as additional energymodules, a technology module, a visualization module, etc.

In one aspect, the energy module 604 can include a port assembly 606,which can be similar to port assembly 2012, that can include a number ofdifferent ports configured to deliver different energy modalities tocorresponding surgical instruments that are connectable thereto. Invarious aspects, the port assembly 606 can include a bipolar port 608,which can be similar to bipolar port 2014, a first monopolar port 610 a,which can be similar to first monopolar port 2016 a, a second monopolarport 610 b, which can be similar to second monopolar port 2016 b, aneutral electrode port 612, which can be similar to neutral electrodeport 2018, and a combination energy port 614, which can be similar tocombination energy port 2020. It should be understood that thisparticular combination of ports is simply provided for illustrativepurposes and alternative combinations of ports and/or energy modalitiesmay be possible for the port assembly 606.

Further, the energy module 604 can include an enclosure 616 that housesinternal components of the energy module 604 therein. In variousaspects, the enclosure 616 can define vents 618 that can vent heatgenerated within the energy module 604 to prevent the energy module 604from overheating. In various aspects, the energy module 604 can furtherinclude a plurality of feet 620 extending from the enclosure 616, whichcan be received in corresponding grooves defined on top of other modulesfor the purposes of stacking the energy module 604 with other modules inthe modular energy system 600.

In one aspect, the header module 602 can include an enclosure 622 whichcan house various internal components of the header module 602 therein,such as a control system 694 (see FIG. 80). In various aspects, thecontrol system 694 can be a printed circuit board (PCB). In variousaspects, the enclosure 622 can define vents 624 that can vent heatgenerated within the header module 602 to prevent the header module 602from overheating. In one aspect, the header module 602 can furtherinclude various physical controls, such as a power button 626, that cancontrol the activation of each module that is connected to the headermodule 602 in the modular energy system 600. In various aspects, theheader module 602 can further include an RFID tag reader 628 which canbe in electrical communication with the control system 694 of the headermodule 602. The RFID tag reader 628 can be configured to read RFID tags,such as clinician specific RFID tags, which can include clinicianspecific default settings and parameters for the header module 602. Forexample, the RFID reader 628 can communicate with a clinician's RFID tagto set the clinician's preferred default parameters of the header module602 prior to operation of the header module 602. In various otheraspects, the RFID reader 628 can read RFID tags that can set defaultparameters associated with specific types of surgical procedures to beperformed.

In one aspect, the enclosure 622 of the header module 602 can define arecess 630. The recess 630 can include a first guidewall 632, a secondguidewall 634, and a base 636 extending from the first guidewall 632 tothe second guidewall 634. In various aspects, the recess 630 can includean electrical connector 638 extending from the base of the recess 630.The electrical connector 638 can be in electrical communication with thecontrol system 694 of the header module 602 such that the control system694 can transmit various electrical signals to electrical componentscoupled to the electrical connector 638, as will be described in moredetail below. In various aspects, the electrical connector 638 can beconnected to the control system 694 with an electrical ribbon 639 (seeFIG. 80).

Referring now to FIGS. 68, 70, and 71, the enclosure 622 of the headermodule 602 can further define a first aperture 640 and a second aperture642. The first and second apertures 640, 642 can be defined in theenclosure 622 and sized to receive latch arms 668, 670 from a latchmechanism 660, as will be described in more detail below.

Referring again to FIGS. 66 and 67, the modular energy system 600 canfurther include a display 644, which can be similar to display screen2006. The display 644 can be configured for displaying a GUI 645, whichcan be similar to GUI 2008. The display 644 can include a touchscreenfor receiving input from users in addition to displaying information.such as statuses of other modules coupled to the header module 602. Thecontrols displayed on the GUI 645 can correspond to the module(s) thatare connected to the header module 602. In some aspects, differentportions or areas of the GUI 645 can correspond to particular modules inthe modular energy system. For example, a first portion or area of theGUI 645 can correspond to a first module, such as the energy module 604,and a second portion or area of the GUI 645 can correspond to a secondmodule, such as another energy module, a technology module, or avisualization module stacked beneath the energy module 604. As differentand/or additional modules are connected or stacked with the modularenergy system 600, the GUI 645 can adjust to accommodate the differentand/or additional controls for each newly added module or removecontrols for each module that is removed. Each portion of the display644 corresponding to a particular module connected to the header module602 can display controls, data, user prompts, and/or other informationcorresponding to that module.

Referring now to FIGS. 68, 72, and 73, the display 644 can include amounting structure 646 that can be utilized for removably coupling thedisplay 644 to the header module 602. In various aspects, the mountingstructure 646 can include a dovetail coupler 648, shown most clearly inFIG. 68, that can include a first sidewall 650 and a second sidewall 652angled relative to the first sidewall 650. The first and secondsidewalls 650, 652 can be angled relative to the display 644 such thatthe first and second sidewalls 650, 652 correspond to the first andsecond guidewalls 632, 634 of the recess 630 of the header module 602.In one aspect, shown in FIGS. 68 and 69, the guidewalls 632, 634 of therecess 630 can align with the sidewalls 650, 652 of the mountingstructure 646 to guide the dovetail coupler 648 through the recess 630of the header module 602 to removably seat the dovetail coupler 648within the recess 630. In one aspect, the first sidewall 650 can movealong the first guidewall 632 and the second sidewall 652 can more alongthe second guidewall 634 to move the dovetail coupler 648 through therecess 630. In one aspect, the dovetail coupler 648 can include a firstbase portion 651 extending transversely from the first sidewall 650 anda second base portion 653 extending from the second sidewall 652. As thedovetail coupler 648 moves through the recess 630, the first and secondbase portions 651, 653 of the dovetail coupler 648 can abut and restagainst the base 636 of the recess 630.

In various aspects, as shown most clearly in FIG. 68, the recess 630 canfurther include a first capture arm 633 extending from the firstguidewall 632 and a second capture arm 635 extending from the secondguidewall 634. In one aspect, the first capture arm 633 can extendaround and capture the first sidewall 650 of the dovetail coupler 648and the second capture arm 635 can extend around and capture the secondsidewall 652 of the dovetail coupler 648 when the dovetail coupler 648is positioned in the recess 630. The first and second capture arms 633,635 can abut the sidewalls 650, 652 of the dovetail coupler 648 toprevent forward rotation of the dovetail coupler 648 out of the recess630, maintaining the position of the display 644 relative to the headermodule 602.

Referring now FIGS. 68, 76, and 77, the dovetail coupler 648 can furtherinclude a recess 654 defined adjacent to the first base portion 651 andthe second base portion 653. The recess 654 can be sized and positionedsuch that, when the dovetail coupler 648 is positioned within the recess630 of the header module 602, as discussed above, the recess 654 of thedovetail coupler 648 can capture the electrical connector 638 of theheader module 602 therein. In various aspects, the recess 654 of thedovetail coupler 648 can include an electrical connector 656 that is inelectrical communication with a control system of the display 644. Inone aspect, when the dovetail coupler 648 is positioned within therecess 654 of the header module 602, the recess 654 of the dovetailcoupler 648 can capture the electrical connector 638 of the headermodule 602 therein and the electrical connector 656 of the display 644can electrically couple with the electrical connector 638 of the headermodule 602. When the electrical connector 638 is electrically coupled tothe electrical connector 656, the control system 694 of the headermodule 602 can transmit electrical signals to the display 644, such aspower signals, communication signals, control signals, etc., to controlvarious operations of the display 644.

In various aspects, referring now to FIGS. 70 and 71, the mountingstructure 646 can further include a latch mechanism 660 that canreleasably latch the display 644 to the header module 602. In variousaspects, the latch mechanism 660 can include a slider button 662, aslider bar 664, and a spring 666. The slider bar 664 can include a firstlatch arm 668 and a second latch arm 670 extending from the slider bar664.

In one aspect, referring to FIG. 73, the mounting structure 646 candefine a recess 672 on a back side 646 b of the mounting structure 646that can house various components of the latch mechanism 660 therein. Invarious aspects, the mounting structure 646 can include a mounting plate674 that defines a plurality of apertures 676 a-g. In one aspect, theapertures 676 a-e can be sized to receive a plurality of fasteners 677a-e therethrough. As shown in FIGS. 70-72, fasteners 677 a-d can extendthrough apertures 676 a-d, respectively, of the mounting plate 674 andremovably couple to mounting holes defined in the mounting structure 646to mount the mounting plate 674 within the recess 672 of the mountingstructure 646. In addition, fastener 677 e can extend through aperture676 e of mounting plate 674 and removably couple to a mounting hole 665defined in the slider bar 664 to removably couple the latching mechanism660 to the mounting plate 674. In various aspects, the aperture 676 ecan be sized to allow for lateral movement of the fastener 677 e withinthe aperture 676 e, as is shown most clearly in FIG. 72 and will bedescribed in more detail below. In various aspects, continuing to referto FIG. 72, aperture 676 f can be sized to receive a first pin 678 aextending from the slider bar 664 and aperture 676 g can be sized toreceive a second pin 678 b extending from the slider bar 664. Theapertures 676 f, 676 g can be sized to allow for lateral movement of thepins 678 a, 678 b therewithin, as shown most clearly in FIGS. 70-72 andwill be described in more detail below.

In one aspect, as shown in FIGS. 70, 71, and 73, the mounting structure646 can define a groove 680 on a front side 646 a of the mountingstructure 646 that can be sized to receive the slider button 662 thereinand allow for lateral movement of the slider button 662 therein. Theslider button 662 can include a pin that can extend through a slotdefined in the groove 680 and can couple to the slider bar 664 such thatlateral movement of the slider button 662 within the groove 680 causeslateral movement of the slider bar 664 within the recess 672. In variousaspects, the slider button 662 can include a lip 663 extending therefromthat can aid in a users ability to move the slider button 662 within thegroove 680.

While a slider button 662 with a lip 663 is shown and described, otherslider buttons are contemplated by the present disclosure. In oneexample aspect, referring to FIG. 74, an alternate slider button 682 isprovided. The slider button 682 can be circular and include a groove 683defined therein that can receive a user's finger therein to aid inmoving the slider button 682 within the groove 680 of the mountingstructure 646. In another example aspect, referring to FIG. 75, analternate slider button 684 is provided. The slider button 684 can be ahalf-circle shape that includes a flat edge 685 that can aid the user inmoving the slider button 684 within the groove 680 of the mountingstructure 646.

Referring to FIG. 77, the mounting structure 646 can define a firstaperture 669 and a second aperture 671 on the front side 646 a thereof.In one aspect, the first latch arm 668 of the latch mechanism 660 canextend from the slider bar 664 through the first aperture 669 and thesecond latch arm 670 of the latch mechanism 660 can extend from theslider bar 664 through the second aperture 671. As shown most clearly inFIGS. 70 and 71, the latch arms 668, 670 can include a base 668 a, 670 aextending from the slider bar 664 and a head 668 b, 670 b extending fromthe base 668 a, 670 a. The heads 668 b, 670 b can include a contactsurface 668 c, 670 c and a cam surface 668 d, 670 d, as will bedescribed in more detail below.

Continuing to refer to FIGS. 70 and 71, as referenced above, the sliderbar 664 can be movably coupled to the slider button 662 such thatlateral movement of the slider button 662 within the groove 680 causeslateral movement of the slider bar 664 within the recess 672. The sliderbutton 662 can be moveable within the groove 680 to transition the latchmechanism 660 between a locked position, shown in FIG. 70, and anunlocked positioned, as shown in FIG. 71. In one aspect, as the sliderbutton 662 moves between the locked position and the unlocked position,the slider bar 664 can translate laterally within the recess 672, whichcan cause the first latch arm 668 and the second latch arm 670 to movewithin the first aperture 669 and the second aperture 671, respectively,as well as cause fastener 677 e to laterally translate within aperture676 e, as well as cause pins 678 a, 678 b to laterally translate withinapertures 676 f, 676 g, respectively. The size of any number of thegroove 680 or the apertures 676 e-f can be defined to determine themaximum displacement of the latch mechanism 660 between the unlocked andlocked positions.

In various aspects, as referenced above, the latch mechanism 660 caninclude a spring 666. The spring 666 can be coupled to an opposite endof the slider bar 664 relative to the slider button 662, as shown inFIGS. 70 and 71. In one aspect, the spring 666 can be mounted within therecess 672 of the mounting structure 646 and can bias the slider bar 664toward the locked position, as shown in FIG. 70, and thus, the bias theslider button 662 within the groove 680 toward a position correspondingto the locked position of the latch mechanism 660. In various otheraspects, the spring 666 can be positioned near the slider button 662such that, as the slider bar 664 moves toward the unlocked position, thespring 666 can expand and bias the slider bar 664 back to the lockedposition.

As referenced above, the display 644 can be coupled to the header module602 by way of the dovetail coupler 648 moving through the recess 630defined in the header module 602. In one aspect, as the dovetail coupler648 moves through the recess 630 and the guidewalls 632, 634 of therecess 630 guide the sidewalls 650, 652 of the mounting structure 646,the latch arms 668, 670 that are extending through the apertures 669,671 of the mounting structure 646 can move through apertures 640, 642,respectively, defined in the enclosure 622 of the header module 602. Asthe latch arms 668, 670 move through the apertures 640, 642, the camsurfaces 668 d, 670 d of the latch arms 668, 670 can abut sidewalls 641,643 defined by the apertures 640, 642 and cam the latch arms 668, 670,and thus, the slider bar 664, toward the unlocked position, allowing thelatch arms 668, 670 to pass through the apertures 640, 642.

In one aspect, once the latch arms 668, 670 pass through the apertures640, 642 and have entered the enclosure 622 of the header module 602,the spring 666 can bias the slider bar 664 back to the locked position,causing contact surfaces 668 c, 670 c of the latch arms 668, 670 toengage latch blocks 658 a, 658 b positioned within the header module602. The latch arms 668, 670 can engage the latch blocks 658 a, 658 band prevent the latch arms 668, 670 from escaping through the apertures640, 642 while the latch mechanism 660 is in the locked position. Asshown in FIG. 71, to release the display 644 from the header module 602,a user can move the slider button 662 within the groove 680, causing thelatch mechanism 660 to move toward the unlocked position. In theunlocked position, the latch arms 668, 670 are released from the latchblocks 658 a, 658 b, allowing the latch arms 668, 670 to be removed fromthe header module 602 through the apertures 640, 642.

Referring now to FIGS. 81-86, a modular energy system 601 is provided,according to at least one aspect of the present disclosure. In variousaspects, the modular energy system 601 can be similar to modular energysystem 600, where like references numbers described throughout thepresent disclosure are utilized in FIGS. 81-86 to identify theirsimilarities and will not be repeated herein for the sake of brevity.

Accessible Memory on Modular Energy System

As referenced elsewhere herein, a modular energy system, such as modularenergy system 600, 601, 2000, can be assembled from a variety ofdifferent modules that can provide different functionality, therebyallowing the modular energy system to be assembled into differentconfigurations to customize the functions and capabilities of themodular energy system by customizing the modules that are included ineach modular energy system. For example, as discussed above, the modularenergy system could include some combination of a header module, such asheader module 602, 2002 (which can include a display screen, such asdisplay screen 2006), an energy module, such as energy module 604, 2004,a technology module, such as technology module 2040, and/or avisualization module, such as visualization module 2042.

In various aspects, the header module of the modular energy system canbe configured to control the system-wide settings of each module andcomponent connected thereto in the modular energy system throughphysical controls, such as physical controls 626, 2011 thereon and/or agraphical user interface (GUI), such as GUI 645, 2008, rendered on thedisplay screen. Such settings could include the activation of themodular energy system, the volume of alerts, footswitch settings,settings icons, appearance or configuration of the user interface, thesurgeon profile logged into the modular energy system, and/or the typeof surgical procedure being performed. The header module can also beconfigured to provide communications, processing, and/or power for themodules that are connected to the header module.

In various aspects, the header module can serve as a central system forthe modules of the modular energy system and surgical instruments thatare operably coupled to the various modules, such as an energy module.The header module can collect data gathered by the surgical instrumentsoperably coupled thereto, which can be stored in a memory for later useor evaluation. Due to worldwide regulations, any personally identifiabledata that is collected by medical equipment, such as the header moduleand the surgical instruments, needs to be accessible to the owners ofthe equipment. It is ideal that the data is easily accessible to theowner such that the owner doesn't need special equipment to retrieve orrisk damaging the information. While it is ideal that this data beeasily accessible to the owners, however, it is also ideal that thisdata is also not readily available to all users of the equipment whereit may be accidentally removed or damaged. Therefore, it is theredesirable to find a simple location to save data collected that is notreadily visible, but can be quickly and easily accessible if needed.

Continuing from the above-provided discussion regarding modular energysystem 600, referring now to FIGS. 66, 67, 87, and 88, the header module602 of the modular energy system 600 can include a memory compartment690 defined in the enclosure 622. Referring particularly to FIG. 88, thememory compartment 690 can be sized to receive a memory card 692, suchas an SD card, therein.

In various aspects, referring to FIG. 66, the memory compartment 690 canbe defined in the enclosure 622 such that, when the display 644 iscoupled to the header module 602, as discussed elsewhere herein, thememory compartment 690 can be hidden and inaccessible. In one aspect,with the display 644 coupled to the header module 602, it is not readilyapparent where the memory card 692 is located, which can mean that thememory card 692 is unlikely to be accidentally removed or damaged. Invarious aspects, referring now to FIG. 67, the memory compartment 690can be defined in the enclosure 622 such that, when the display 644 ofthe modular energy system 600 is uncoupled from the header module 602,the memory compartment 690 is visible and accessible to an owner of theheader module 602. In this sense, the memory card 692 can be readilyretrieved by a trained representative or technician by simply uncouplingthe display 644 from the header module 602, such as by releasing thedisplay 644 with the slider button 662 of the latch mechanism 660, asdescribed elsewhere herein.

Defining the memory compartment 690 at the front of the header module602, where it will be covered by the display 644, is beneficial asopposed to defining the memory compartment 690 at another location onthe header module 602, such as on a back side of the header module 602.In one aspect, referring to FIG. 80, as an example, the front side ofthe header module 602 can include extra space compared to the backsideof the header module 602, owing to the positioning of the control system694 within the header module 602. Additionally, defining the memorycompartment 690 at the front of the header module 602 can providenatural protection from fluid ingress, owing to the positioning of thedisplay 644 in front of the memory compartment 690. Further, definingthe memory compartment 690 at the front of the header module 602 can bebeneficial in that it that the memory card 692 can be added to the mainboard of the control system 694 without the need for any additionalconnections, which can reduce cost, as well as improve signal integrity.

In various aspects, referring now to FIGS. 67, 87, and 88, the headermodule 602 can further include a door 696 that is sized to cover thememory compartment 690. In one aspect, the door 696 can provideadditional protection against fluid ingress when the header module 602is in use, while also providing the benefit of making the memory card692 not readily visible. In various aspects, the enclosure 622 candefine a lip 698 that surrounds the memory compartment 690. The lip 698can be sized such that a user is able to insert the memory card 692 intothe memory compartment 690, but the lip 698 prevents the door 696 frommoving into the memory compartment 690. In one aspect, the door 696 canbe seated on the lip 698 such that, as shown in FIG. 87, the door 696 isflush with the surface of the enclosure 622 of the header module 602.

In various aspects, the door 696 can include an aperture 700 that issized to receive a fastener, such as a screw, therethrough. In oneaspect, enclosure 622 can further include a mounting hole 702, shown inFIG. 88, that can sized to receive the fastener therein. In one exampleoperation, to assembly the door 696 to the header module 602, a user canseat the door 696 on the lip 698 of the memory compartment 690, coveringthe memory compartment 690 and a memory card 692 potentially storedtherein. Then, a user can insert the fastener through the aperture 700and into the mounting hole 702 to couple the door 696 to the enclosure622. The use of the door 696 and the fastener can allow for quick andeasy accessibility of the memory compartment 690 (and the memory card692) if needed. The use of the door 696 also provides additionalprotection at times when the display 644 is uncoupled to the headermodule 602, such as during assembly or shipping of the same.

Referring to FIGS. 89 and 90, a header module 704 is provided, accordingto at least one aspect of the present disclosure. In one aspect, theheader module 704 can be similar to header module 602. In variousaspects, the header module 704 can include a memory compartment 706,similar to memory compartment 690, defined in an enclosure 708 of theheader module 704. The memory compartment 706 can be sized to receive amemory card, such as memory card 692, therein.

In various aspects, similar to memory compartment 690, the memorycompartment 706 can be defined in the enclosure 708 such that, when adisplay, such as display 644, is coupled from the header module 704, thememory compartment 706 can be hidden and inaccessible to an owner of theheader module 704. In one aspect, with the display coupled to the headermodule 704, it is not readily apparent where the memory card is located,which can mean that the memory card is unlikely to be accidentallyremoved or damaged. In various aspects, similar to memory compartment690, the memory compartment can be defined in the enclosure 708 suchthat, when the display is uncoupled from the header module 704, thememory compartment 706 is visible and accessible to an owner of theheader module 704. In this sense, the memory card can be readilyretrieved by a trained representative or technician by simply uncouplingthe display from the header module 704, such as by releasing the displaywith a slider button of a latch mechanism, as described elsewhereherein.

Defining the memory compartment 706 at the front of the header module704, where it will be covered by the display, is beneficial as opposedto defining the memory compartment 706 at another location on the headermodule 704, such as on a back side of the header module 704. In oneaspect, similar to memory compartment 690, the front side of the headermodule 704 can include extra space compared to the backside of theheader module, owing to the positioning of the control system, such ascontrol system 694, within the header module 704. Additionally, definingthe memory compartment 706 at the front of the header module 704 canprovide natural protection from fluid ingress, owing to the positioningof the display in front of the memory compartment 706. Further, definingthe memory compartment 706 at the front of the header module 704 can bebeneficial in that it that the memory card can be added to the mainboard of the control system without the need for any additionalconnections, which can reduce cost, as well as improve signal integrity.

In various aspects, referring now to FIGS. 89 and 90, the header module704 can further include a door 710 that is sized to cover the memorycompartment 706. In one aspect, the door 710 can provide additionalprotection against fluid ingress when the header module 602 is in use,while also providing the benefit of making the memory card not readilyvisible. In various aspects, the enclosure 708 can define a lip 712,similar to lip 698, that surrounds the memory compartment 706. The lip712 can be sized such that a user is able to insert the memory card intothe memory compartment 706, but the lip 712 prevents the door 710 frommoving into the memory compartment 706. In one aspect, the door 710 canbe seated on the lip 712 such that, as shown in FIG. 89, the door 710 isflush with the surface of the enclosure 708 of the header module 704. Invarious aspects, the enclosure 708 can further define notches 714 a, 714b, as will be discussed in more detail below.

In various aspects, referring now to FIGS. 89 and 90, the door 710 caninclude a mounting structure that includes a first mounting arm 718 aand a second mounting arm 718 b. Each of the mounting arms 718 a, 718 bcan include a base 720 a, 720 b, an arm 722 a, 722 b extending from thebase 720 a, 720 b, and a hook 724 a, 724 b extending from the arm 722 a,722 b. As shown in FIG. 90, the mounting arms 718 a, 718 b extend fromthe door 696 such that, when the door 710 is moved toward the lip 712 ofthe memory compartment 706, the mounting arms 718 a, 718 b can extendthrough the memory compartment 706. The hooks 724 a, 724 b can include acam surface 726 a, 726 b that can abut cam surfaces 727 a, 727 b of thelip 712 as the mounting arms 718 a, 718 b move through the memorycompartment 706, causing the mounting arms 718 a, 718 b to flex awayfrom the lip 712, allowing the mounting arms 718 a, 718 b to enter thememory compartment 706. Once the hooks 724 a, 724 b pass the lip 712,the cam surfaces 726 a, 726 b can disengage the lip 712, causing themounting arms 718 a, 718 b to bias toward their unflexed positions, asshown in FIG. 90. In the unflexed position, contact surfaces 728 a, 728b of the hooks 724 a, 724 b can engage the notches 714 a, 714 b of theenclosure 708, preventing the mounting arms 718 a, 718 b from moving outof the memory compartment 706, and thus, preventing the door 710 frommoving away from the memory compartment 706.

In one aspect, to remove the door 710 from the memory compartment 706,referring to FIG. 88, a user can move bases 720 a, 720 b of the mountingarms 718 a, 718 b, such as with their fingers, toward one another.Moving the bases 720 a, 720 b towards one another causes contactsurfaces 728 a, 728 b of mounting arms 718 a, 718 b to move out ofoperable engagement with notches 714 a, 714 b, allowing the mountingarms 718 a, 718 b to be removed from the memory compartment 706, andthus, allowing the door 710 to be moved away from the memory compartment706. The use of the door 710 can allow for quick and easy accessibilityof the memory compartment 706 (and the memory card) if needed withoutthe need of an additional tool, such as a screwdriver. The use of thedoor 710 also provides additional protection at times when the displayis uncoupled to the header module 704, such as during assembly orshipping of the same.

PCB Mounted Connector Biasing with Crush Ribs

As referenced elsewhere herein, a modular energy system, such as modularenergy system 600, 601, 2000, can be assembled from a variety ofdifferent modules that can provide different functionality, therebyallowing the modular energy system to be assembled into differentconfigurations to customize the functions and capabilities of themodular energy system by customizing the modules that are included ineach modular energy system. For example, as discussed above, the modularenergy system could include some combination of a header module, such asheader module 602, 2002 (which can include a display screen, such asdisplay screen 2006), an energy module, such as energy module 604, 2004,a technology module, such as technology module 2040, and/or avisualization module, such as visualization module 2042.

In various aspects, the header module of the modular energy system canbe configured to control the system-wide settings of each module andcomponent connected thereto in the modular energy system throughphysical controls, such as physical controls 626, 2011 thereon and/or agraphical user interface (GUI), such as GUI 645, 2008, rendered on thedisplay screen. Such settings could include the activation of themodular energy system, the volume of alerts, footswitch settings,settings icons, appearance or configuration of the user interface, thesurgeon profile logged into the modular energy system, and/or the typeof surgical procedure being performed. The header module can also beconfigured to provide communications, processing, and/or power for themodules that are connected to the header module.

In various aspects, the header module can include a control system, suchas printed circuit board (PCB), that can control various functions ofthe header module, such as communicating data and power to a display orvarious other modules coupled to the header module. In one aspect, thecontrol system can be held in place within the header module by crushribs, which is a foam-like material that has very large tolerances.Owing to the tolerances of crush ribs, the PCB can vary in positionwithin the header module.

In one aspect, the PCB can include a variety of externally accessibleconnectors mounted thereon, such as connectors 740 illustrated in FIG.91. The connectors 740 can be accessible through apertures 742 definedin a panel of the header module 744, such as the rear panel 746 of theheader module 744. These connectors 740 allow for external equipment tobe connected to the PCB to control various aspects of the PCB, and thus,the header module 744.

As referenced above, the PCB can be held in place within the headermodule by crush ribs, which can cause the PCB to vary in positiontherein. As a result of the varying position of the PCB, the externallyaccessible connectors 740 can also vary in position within the headermodule 744. To accommodate for the varying position in the PCB mountedconnecters 740 within the header module 744, the apertures 742 in thepanel 746 would need to be large enough to allow the connectors 740 tovary in position. However, apertures sized to accommodate the varyingpositions of the PCB mounted connectors are not ideal and couldpotentially allow access to the internals of the header moduletherethrough.

Referring now to FIGS. 92 and 93, a header module 750 is provided,according to at least one aspect of the present disclosure. The headermodule 750 can include an enclosure 752 and a PCB 754 positioned withinthe enclosure 752. In one aspect, the PCB 754 can control variousfunctions of the header module 750, such as communicating data and powerto a display or various other modules operably coupled to the headermodule 750. In various aspects, the PCB 754 can be similar to othercontrol systems disclosed herein, such as control system 694.

In various aspects, the PCB 754 can include a plurality of connectors756 positioned thereon. The connectors 756 can be sized and configuredto operably couple to external control systems that can controloperation of the PCB 754, and thus, the header module 750. The enclosure752 of the header module 750 can define apertures 758 therein that canbe sized to allow for external connectors of the external control systemto be coupled to the connectors 756 positioned on the PCB 754.

In various aspects, the header module 750 can further include a numberof crush ribs 760 positioned therein. The crush ribs 760 can bepositioned beneath the PCB 754 and can be utilized to control theposition of the connectors 756 of the PCB 754 within the enclosure 752and relative to the apertures 758. In one aspect, the crush ribs 760 canbias the rear end of the control system upward, such as is shown in FIG.93, which can guarantee that the connectors 756 “touch-off” on the topside of the apertures 758 of the enclosure 752. The use of crush ribs760 simplifies the tolerance stack of the crush ribs and allows theapertures 758 to be small enough to prevent access to the internals ofthe header module 750.

Screen Construction on Capital System

As referenced elsewhere herein, a modular energy system, such as modularenergy system 600, 601, 2000, can be assembled from a variety ofdifferent modules that can provide different functionality, therebyallowing the modular energy system to be assembled into differentconfigurations to customize the functions and capabilities of themodular energy system by customizing the modules that are included ineach modular energy system. For example, as discussed above, the modularenergy system could include some combination of a header module, such asheader module 602, 2002 (which can include a display screen, such asdisplay screen 2006), an energy module, such as energy module 604, 2004,a technology module, such as technology module 2040, and/or avisualization module, such as visualization module 2042.

In various aspects, the header module of the modular energy system canbe configured to control the system-wide settings of each module andcomponent connected thereto in the modular energy system throughphysical controls, such as physical controls 626, 2011 thereon and/or agraphical user interface (GUI), such as GUI 645, 2008, rendered on thedisplay screen. Such settings could include the activation of themodular energy system, the volume of alerts, footswitch settings,settings icons, appearance or configuration of the user interface, thesurgeon profile logged into the modular energy system, and/or the typeof surgical procedure being performed. The header module can also beconfigured to provide communications, processing, and/or power for themodules that are connected to the header module.

Currently, there is a trend towards touchscreen displays on equipmentbecause it both provides increased functionality and flexibility overknobs or buttons. As references elsewhere herein, the display is able tobe coupled to and decoupled from the header module, such as with thelatch mechanism 660, as an example The ability to removably couple thedisplay to the header modules provides a number of benefits. As oneexample, this allows the display to be manufactured separate from othercomponents of the modular energy system. As another example, this allowsa user to select between a variety of different displays for use withthe modular energy system, such as displays with varying sizes and/ordegrees of functionality. The ability to decouple the display from theheader module also is beneficial from a shipping perspective, while alsoallowing for ease of maintenance should the display require the same. Itis therefore desirable to continue to improve the removable display toprovide additional benefits, such as providing a simple construction ofthe display that reduces part count, allows separation of the componentsof the display, and fully encloses all internal portions of the display.

Referring now to FIGS. 94-96, a display assembly 770 is provided,according to at least one aspect of the present disclosure. In variousembodiments, the display assembly 770 can include a rear enclosure 772and a liquid crystal display (LCD) subassembly 774 removably coupleableto the rear enclosure 772, as will be discussed in more detail below. Inone aspect, the rear enclosure 772 can be similar to mounting structure646. In one aspect, the display assembly 770 can be similar to otherdisplays described elsewhere herein.

In various embodiments, the LCD subassembly 774 can include an LCDtouchscreen 776, a front cover 780, and an adhesive 778, such as adouble-sided adhesive, configured to couple the LCD touchscreen 776 andthe front cover 780. In one aspect, the LCD touchscreen 776 can includea coverglass that can be coupled to the LCD touchscreen 776 in asuitable manner, such as with liquid adhesive or air bonding, asexamples. In various embodiments, the front cover 780 and the LCDtouchscreen 776 can be coupled together in various other manners otherthan with the adhesive 778, such as with, screws, press-fit, or thelike.

Referring to FIGS. 94, 95, and most particularly to FIG. 97, the frontcover 780 can include a plurality of latches 782 extending therefrom.The plurality of latches 782 can allow the LCD subassembly 774 to beremovably coupled to the rear enclosure 772, as will be discussed inmore detail below. In one aspect, the plurality of latches 782 canextend around the perimeter of the front cover 780. In various otherembodiments, the plurality of latches 782 can extend from discretelocations of the front cover 780, such as from only one side of thefront cover or multiple sides of the front cover. In variousembodiments, each of the latches 782 can include a base 784 extendedfrom the front cover 780, a latch arm 786 extending from the base 784,and a latch head 788 extending from the latch arm 786. The latch head788 can include a cam surface 790 and a contact surface 792.

Continuing to refer to FIG. 97, the rear enclosure 772 can define anouter lip 773 and a recess 775 sized to receive the LCD subassembly 774therein. The lip 773 can be sized to cover the internals of the displayassembly 770 when the LCD subassembly 774 is positioned in the recess775. In various embodiments, the rear enclosure 772 can define aplurality of notches 794. The plurality of notches 794 can be defined inthe rear enclosure 772 to correspond to the latches 782 extending fromthe front cover 780.

In one aspect, when assembling the display assembly 770, the LCDsubassembly 774 can be moved towards the recess 775 of the rearenclosure 772. As the latches 782 move through the recess 775, the camsurfaces 790 of the latch heads 788 can engage cam surfaces 795 of therear enclosure 772. The cam surfaces 795 of the rear enclosure 772 cancause the latches 782 to flex away from the notches 794 toward a flexposition as the cam surfaces 790 of the latches 782 move along the camsurfaces 795 of the rear enclosure 772. Once the latch head 788traverses the cam surface 795 of the rear enclosure 772, the latch head788 can be biased back toward and unflexed position and snap into thenotches 794 defined in the rear enclosure 772, as shown in FIG. 97. Withthe latch head 788 positioned in the notch 794, the contact surface 792of the latch head 788 can engage contact surface 796 of the notch 794,preventing the latch head 788 from escaping the notch 794, thus,preventing the LCD subassembly 774 from moving relative to the rearenclosure 772. In one aspect, the rear enclosure 772 can define holestherein that can allow for access to the latches 782 within the rearenclosure 772, thereby allowing a user to move the latch heads 788 outof the notches 794, which allows the user to remove from LCD subassembly774 from the rear enclosure 772.

In various embodiments, the rear enclosure 772 can include an electricalconnector 798. In one aspect, the electrical connector 798 can besimilar to electrical connector 656. Similarly, the LCD subassembly 774can include an electrical connector. In one aspect, when the LCDsubassembly 774 is positioned in the rear enclosure 772, as referencedabove, the electrical connector of the LCD subassembly 774 canelectrically couple with the electrical connector 798 of the rearenclosure 772. In various embodiments, the electrical connection can bemade with a wire harness and a connector that slides into the rearenclosure 772. Once assembled, the display assembly 770 can be coupledto a header module, similar to described elsewhere herein. In oneexample embodiment, the electrical connector 798 of the rear enclosure772 could electrically couple to an electrical connector, likeelectrical connector 638, of a header module, such that the headermodule can transmit control signals to the display assembly 770 and cancontrol various operations thereof. In one aspect, the header modularcan control a GUI of the LCD touchscreen 776 to provided status updatesof various modules operably coupled to the header module. In variousembodiments, the header module can communicate with the display assembly770 such that user inputs provided to the LCD touchscreen 776 can becommunicated to the header module to control various aspects of themodular energy system. In one aspect, the display assembly 770 couldinclude a bezel around the LCD touchscreen 776, such as around thecoverglass, and the header module can control light emitted from thebezel to create a highly aesthetic view with maximum usable space.

It should be understood that various aspects of the disclosure describedherein, such as the disclosure associated with FIGS. 66-97, as anexample, may be utilized independently, or in combination, with oneanother.

EXAMPLES

Various aspects of the module energy systems comprising a header asdescribed herein with reference to FIGS. 66-97 are set out in thefollowing numbered examples.

Example 1. A modular energy system comprising a header module comprisingan enclosure and a display comprising a coupler. The enclosure defines arecess. The recess comprises a first guidewall and a second guidewall.The coupler is removably positionable in the recess. The couplercomprises a first sidewall, wherein the first guidewall is configured toguide the first sidewall as the coupler moves through the recess, and asecond sidewall, wherein the second guidewall is configured to guide thesecond sidewall as the coupler moves through the recess.

Example 2. The modular energy system of Example 1, wherein the firstsidewall is angled relative to the second sidewall.

Example 3. The modular energy system of any one or more of Examples 1through 2, wherein the recess further comprises a first capture armconfigured to at least partially surround the first sidewall as thecoupler moves through the recess and a second capture arm configured toat least partially surround the second sidewall as the coupler movesthrough the recess, wherein the first capture arm and the second capturearm are configured to prevent the coupler from rotating away from therecess.

Example 4. The modular energy system of any one or more of Examples 1through 3, wherein the header module comprises a first electricalconnector, wherein the recess further comprises a second electricalconnector, and wherein the first guidewall and the second guidewall areconfigured to guide the second electrical connector toward the firstelectrical connector as the coupler moves through the recess.

Example 5. The modular energy system of any one or more of Examples 1through 4, wherein the display further comprises a latch mechanismconfigured to removably latch the display to the header module.

Example 6. The modular energy system of Example 5, wherein the latchmechanism comprises a first latch arm extending from the display, andwherein the enclosure of the header module further defines a firstaperture configured to receive the first latch arm therethrough.

Example 7. The modular energy system of Example 6, wherein the firstlatch arm is movable between a locked position and an unlocked position,and wherein the first latch arm is prevented from moving through thefirst aperture in the locked position.

Example 8. The modular energy system of Example 7, wherein the latchmechanism further comprises a slider button configured to move the firstlatch arm between the locked position and the unlocked position.

Example 9. The modular energy system of Example 8, wherein the latchmechanism further comprises a spring configured to bias the first latcharm toward the locked position.

Example 10. The modular energy system of any one or more of Examples 6through 9, wherein the latch mechanism comprises a slider bar, whereinthe first latch arm extends from the slider bar, wherein the latchmechanism further comprises a second latch arm extending from the sliderbar, and wherein the enclosure of the header module further defines asecond aperture configured to receive the second latch arm therethrough.

Example 11. The modular energy system of any one or more of Examples 1through 10, wherein the enclosure further defines a memory compartmentconfigured to receive a memory card therein, and wherein the memory cardis hidden when the display is coupled to the header module.

Example 12. The modular energy system of Example 11, further comprisinga door configured to cover the memory compartment.

Example 13. A modular energy system comprising a header modulecomprising an enclosure, a display comprising a coupler, and a latchmechanism configured to removably latch the display to the headermodule. The enclosure defines a recess. The coupler is removablypositionable in the recess.

Example 14. The modular energy system of Example 13, wherein the headermodule comprises a first electrical connector, wherein the recessfurther comprises a second electrical connector, and wherein the firstelectrical connector is configured to electrically couple to the secondelectrical connector.

Example 15. The modular energy system of any one or more of Examples 13through 14, wherein the latch mechanism comprises a first latch armextending from the display, wherein the enclosure of the header modulefurther defines a first aperture configured to receive the first latcharm therethrough.

Example 16. The modular energy system of Example 15, wherein the firstlatch arm is movable between a locked position and an unlocked position,and wherein the latch mechanism further comprises a slider buttonconfigured to move the first latch arm between the locked position andthe unlocked position.

Example 17. A modular energy system comprising a header modulecomprising a housing and a display comprising a coupler. The housingdefines a recess. The recess comprises a first guidewall, a secondguidewall angled relative to the first guidewall, and a first electricalconnector. The coupler is removably positionable in the recess. Thecoupler comprises a second electrical connector configured to removablycouple to the first electrical connector, a first sidewall configured tomove along the first guidewall, and a second sidewall configured to movealong the second guidewall, wherein the first sidewall and the secondsidewall are configured to guide the second electrical connector towardthe first electrical connector.

Example 18. The modular energy system of Example 17, wherein the displayfurther comprises a latch mechanism configured to removably latch thedisplay to the header module.

Example 19. The modular energy system of Example 18, wherein the latchmechanism comprises a first latch arm extending from the display,wherein the housing of the header module further defines a firstaperture configured to receive the first latch arm therethrough.

Example 20. The modular energy system of Example 19, wherein the firstlatch arm is movable between a locked position and an unlocked position,and wherein the latch mechanism further comprises a slider buttonconfigured to move the first latch arm between the locked position andthe unlocked position.

EXAMPLES

Various aspects of assembling a connector subassembly for a module of amodular energy system as described herein are set out in the followingnumbered examples.

Example 1. A method of assembling a backplane connector subassembly fora module of a modular energy system, wherein the backplane connectorsubassembly physically and electrically connects at least two modulesstacked on top of one another, the method comprising: providing a backpanel defining an inner surface; attaching a first support member to theinner surface of the back panel, wherein the first support member isconfigured to support an upstream connector; attaching a second supportmember to the inner surface of the back panel, wherein the secondsupport member is configured to support a downstream connector;attaching the upstream connector to the back panel by sliding a firstmating hole defined in the upstream connector onto the first supportmember; and attaching the downstream connector to the back panel by asliding a second mating hole defined in the downstream connector ontothe second support member.

Example 2. The method of Example 1, further comprising attaching asupport ledge to the inner surface of the back panel between the firstand second support members.

Example 3. The method of Example 2, wherein the upstream connectorcomprises a rib extending from the protrusion.

Example 4. The method of Example 3, further comprising resting the ribof the upstream Example 5. The method of any one or more of Examples 2through 4, comprising attaching the support ledge offset from the firstsupport member.

Example 6. The method of any one or more of Examples 1 through 5,wherein the upstream connector comprises a protrusion that defines thefirst mating hole.

Example 7. The method of any one or more of Examples 1 through 6,wherein the downstream connector comprises a protrusion that defines thesecond mating hole.

Example 8. A method of assembling a backplane connector subassembly fora module of a modular energy system, wherein the backplane connectorsubassembly physically and electrically connects at least two modulesstacked on top of one another, the method comprising: providing a backpanel defining an inner surface; attaching a first set of two supportmembers to the inner surface of the back panel, wherein the first set oftwo support members is configured to support an upstream connector;attaching a second set of two support members to the inner surface ofthe back panel, wherein the second set of two support members isconfigured to support a downstream connector; attaching the upstreamconnector to the back panel by sliding first and second mating holesdefined in the upstream connector onto the first set of two supportmembers; and attaching the downstream connector to the back panel by asliding first and second mating holes defined in the downstreamconnector onto the second set of two support members.

Example 9. The method of Example 8, further comprising attaching a setof two support ledges to the inner surface of the back panel between thefirst set and the second set of two support

Example 10. The method of Example 9, wherein the upstream connectorcomprises a first rib extending from the first protrusion and a secondrib extending from the second protrusion.

Example 11. The method of Example 10, further comprising resting thefirst and second ribs of the upstream connector onto the set of twosupport ledges.

Example 12. The method of any one or more of Examples 8 through 11,comprising attaching the set of two support ledges offset from the firstset of two support members.

Example 13. The method of any one or more of Examples 8 through 11,wherein the upstream connector comprises a first protrusion that definesthe first mating hole and a second protrusion that defines the secondmating hole.

Example 14. The method of claim 8, wherein the downstream connectorcomprises a first protrusion that defines the first mating hole and asecond protrusion that defines the second mating hole.

Example 15. A method of assembling a display assembly for a headermodule of a modular energy system, the method comprising providing arear enclosure defining a recess and a plurality of notches, forming adisplay sub-assembly by coupling a touchscreen to a front cover, whereinthe front cover comprises a plurality of latches, and releasablycoupling the display sub-assembly to the rear enclosure by positioningthe plurality of latches of the front cover in the plurality of notchesof the rear enclosure.

Example 16. The method of Example 15, wherein the rear enclosurecomprises a first electrical connector, wherein the touchscreencomprises a second electrical connector, and wherein the method furthercomprises electrically coupling the first electrical connector to thesecond electrical connector.

Example 17. The method of Examples 15 or 16, further comprising couplinga latch mechanism to the rear enclosure, wherein the latch mechanism isconfigured to releasable couple the display assembly to the headermodule.

Example 18. The method of Example 17, wherein coupling the latchmechanism to the rear enclosure comprises positioning a slider bar inthe recess, positioning a mounting plate in the recess, coupling themounting plate to the slider bar, and coupling the mounting plate to therear enclosure.

Example 19. The method of Example 18, wherein the mounting platecomprises a first aperture and a second aperture, wherein the slider barcomprises a mounting hole and a pin extending therefrom, and whereincoupling the mounting plate to the slider bar comprising positioning thepin in the first aperture, aligning the second aperture with themounting hole, extending a fastener through the second aperture and intothe mounting hole, and coupling the fastener to the mounting hole.

Example 20. The method of any one or more of Examples 17 through 19,wherein the rear enclosure further defines a first aperture and a secondaperture, wherein the latch mechanism comprises a first arm and a secondarm, and wherein the method further comprises extending the first armthrough the first aperture and extending the second arm through thesecond aperture.

While several forms have been illustrated and described, it is not theintention of Applicant to restrict or limit the scope of the appendedclaims to such detail. Numerous modifications, variations, changes,substitutions, combinations, and equivalents to those forms may beimplemented and will occur to those skilled in the art without departingfrom the scope of the present disclosure. Moreover, the structure ofeach element associated with the described forms can be alternativelydescribed as a means for providing the function performed by theelement. Also, where materials are disclosed for certain components,other materials may be used. It is therefore to be understood that theforegoing description and the appended claims are intended to cover allsuch modifications, combinations, and variations as falling within thescope of the disclosed forms. The appended claims are intended to coverall such modifications, variations, changes, substitutions,modifications, and equivalents.

The foregoing detailed description has set forth various forms of thedevices and/or processes via the use of block diagrams, flowcharts,and/or examples. Insofar as such block diagrams, flowcharts, and/orexamples contain one or more functions and/or operations, it will beunderstood by those within the art that each function and/or operationwithin such block diagrams, flowcharts, and/or examples can beimplemented, individually and/or collectively, by a wide range ofhardware, software, firmware, or virtually any combination thereof.Those skilled in the art will recognize that some aspects of the formsdisclosed herein, in whole or in part, can be equivalently implementedin integrated circuits, as one or more computer programs running on oneor more computers (e.g., as one or more programs running on one or morecomputer systems), as one or more programs running on one or moreprocessors (e.g., as one or more programs running on one or moremicroprocessors), as firmware, or as virtually any combination thereof,and that designing the circuitry and/or writing the code for thesoftware and or firmware would be well within the skill of one of skillin the art in light of this disclosure. In addition, those skilled inthe art will appreciate that the mechanisms of the subject matterdescribed herein are capable of being distributed as one or more programproducts in a variety of forms, and that an illustrative form of thesubject matter described herein applies regardless of the particulartype of signal bearing medium used to actually carry out thedistribution.

Instructions used to program logic to perform various disclosed aspectscan be stored within a memory in the system, such as dynamic randomaccess memory (DRAM), cache, flash memory, or other storage.Furthermore, the instructions can be distributed via a network or by wayof other computer readable media. Thus a machine-readable medium mayinclude any mechanism for storing or transmitting information in a formreadable by a machine (e.g., a computer), but is not limited to, floppydiskettes, optical disks, compact disc, read-only memory (CD-ROMs), andmagneto-optical disks, read-only memory (ROMs), random access memory(RAM), erasable programmable read-only memory (EPROM), electricallyerasable programmable read-only memory (EEPROM), magnetic or opticalcards, flash memory, or a tangible, machine-readable storage used in thetransmission of information over the Internet via electrical, optical,acoustical or other forms of propagated signals (e.g., carrier waves,infrared signals, digital signals, etc.). Accordingly, thenon-transitory computer-readable medium includes any type of tangiblemachine-readable medium suitable for storing or transmitting electronicinstructions or information in a form readable by a machine (e.g., acomputer).

As used in any aspect herein, the term “control circuit” may refer to,for example, hardwired circuitry, programmable circuitry (e.g., acomputer processor including one or more individual instructionprocessing cores, processing unit, processor, microcontroller,microcontroller unit, controller, digital signal processor (DSP),programmable logic device (PLD), programmable logic array (PLA), orfield programmable gate array (FPGA)), state machine circuitry, firmwarethat stores instructions executed by programmable circuitry, and anycombination thereof. The control circuit may, collectively orindividually, be embodied as circuitry that forms part of a largersystem, for example, an integrated circuit (IC), an application-specificintegrated circuit (ASIC), a system on-chip (SoC), desktop computers,laptop computers, tablet computers, servers, smart phones, etc.Accordingly, as used herein “control circuit” includes, but is notlimited to, electrical circuitry having at least one discrete electricalcircuit, electrical circuitry having at least one integrated circuit,electrical circuitry having at least one application specific integratedcircuit, electrical circuitry forming a general purpose computing deviceconfigured by a computer program (e.g., a general purpose computerconfigured by a computer program which at least partially carries outprocesses and/or devices described herein, or a microprocessorconfigured by a computer program which at least partially carries outprocesses and/or devices described herein), electrical circuitry forminga memory device (e.g., forms of random access memory), and/or electricalcircuitry forming a communications device (e.g., a modem, communicationsswitch, or optical-electrical equipment). Those having skill in the artwill recognize that the subject matter described herein may beimplemented in an analog or digital fashion or some combination thereof.

As used in any aspect herein, the term “logic” may refer to an app,software, firmware and/or circuitry configured to perform any of theaforementioned operations. Software may be embodied as a softwarepackage, code, instructions, instruction sets and/or data recorded onnon-transitory computer readable storage medium. Firmware may beembodied as code, instructions or instruction sets and/or data that arehard-coded (e.g., nonvolatile) in memory devices.

As used in any aspect herein, the terms “component,” “system,” “module”and the like can refer to a computer-related entity, either hardware, acombination of hardware and software, software, or software inexecution.

As used in any aspect herein, an “algorithm” refers to a self-consistentsequence of steps leading to a desired result, where a “step” refers toa manipulation of physical quantities and/or logic states which may,though need not necessarily, take the form of electrical or magneticsignals capable of being stored, transferred, combined, compared, andotherwise manipulated. It is common usage to refer to these signals asbits, values, elements, symbols, characters, terms, numbers, or thelike. These and similar terms may be associated with the appropriatephysical quantities and are merely convenient labels applied to thesequantities and/or states.

A network may include a packet switched network. The communicationdevices may be capable of communicating with each other using a selectedpacket switched network communications protocol. One examplecommunications protocol may include an Ethernet communications protocolwhich may be capable permitting communication using a TransmissionControl Protocol/Internet Protocol (TCP/IP). The Ethernet protocol maycomply or be compatible with the Ethernet standard published by theInstitute of Electrical and Electronics Engineers (IEEE) titled “IEEE802.3 Standard”, published in December, 2008 and/or later versions ofthis standard. Alternatively or additionally, the communication devicesmay be capable of communicating with each other using an X.25communications protocol. The X.25 communications protocol may comply orbe compatible with a standard promulgated by the InternationalTelecommunication Union-Telecommunication Standardization Sector(ITU-T).

Alternatively or additionally, the communication devices may be capableof communicating with each other using a frame relay communicationsprotocol. The frame relay communications protocol may comply or becompatible with a standard promulgated by Consultative Committee forInternational Telegraph and Telephone (CCITT) and/or the AmericanNational Standards Institute (ANSI). Alternatively or additionally, thetransceivers may be capable of communicating with each other using anAsynchronous Transfer Mode (ATM) communications protocol. The ATMcommunications protocol may comply or be compatible with an ATM standardpublished by the ATM Forum titled “ATM-MPLS Network Interworking 2.0”published August 2001, and/or later versions of this standard. Ofcourse, different and/or after-developed connection-oriented networkcommunication protocols are equally contemplated herein.

Unless specifically stated otherwise as apparent from the foregoingdisclosure, it is appreciated that, throughout the foregoing disclosure,discussions using terms such as “processing,” “computing,”“calculating,” “determining,” “displaying,” or the like, refer to theaction and processes of a computer system, or similar electroniccomputing device, that manipulates and transforms data represented asphysical (electronic) quantities within the computer system's registersand memories into other data similarly represented as physicalquantities within the computer system memories or registers or othersuch information storage, transmission or display devices.

One or more components may be referred to herein as “configured to,”“configurable to,” “operable/operative to,” “adapted/adaptable,” “ableto,” “conformable/conformed to,” etc. Those skilled in the art willrecognize that “configured to” can generally encompass active-statecomponents and/or inactive-state components and/or standby-statecomponents, unless context requires otherwise.

The terms “proximal” and “distal” are used herein with reference to aclinician manipulating the handle portion of the surgical instrument.The term “proximal” refers to the portion closest to the clinician andthe term “distal” refers to the portion located away from the clinician.It will be further appreciated that, for convenience and clarity,spatial terms such as “vertical”, “horizontal”, “up”, and “down” may beused herein with respect to the drawings. However, surgical instrumentsare used in many orientations and positions, and these terms are notintended to be limiting and/or absolute.

Those skilled in the art will recognize that, in general, terms usedherein, and especially in the appended claims (e.g., bodies of theappended claims) are generally intended as “open” terms (e.g., the term“including” should be interpreted as “including but not limited to,” theterm “having” should be interpreted as “having at least,” the term“includes” should be interpreted as “includes but is not limited to,”etc.). It will be further understood by those within the art that if aspecific number of an introduced claim recitation is intended, such anintent will be explicitly recited in the claim, and in the absence ofsuch recitation no such intent is present. For example, as an aid tounderstanding, the following appended claims may contain usage of theintroductory phrases “at least one” and “one or more” to introduce claimrecitations. However, the use of such phrases should not be construed toimply that the introduction of a claim recitation by the indefinitearticles “a” or “an” limits any particular claim containing suchintroduced claim recitation to claims containing only one suchrecitation, even when the same claim includes the introductory phrases“one or more” or “at least one” and indefinite articles such as “a” or“an” (e.g., “a” and/or “an” should typically be interpreted to mean “atleast one” or “one or more”); the same holds true for the use ofdefinite articles used to introduce claim recitations.

In addition, even if a specific number of an introduced claim recitationis explicitly recited, those skilled in the art will recognize that suchrecitation should typically be interpreted to mean at least the recitednumber (e.g., the bare recitation of “two recitations,” without othermodifiers, typically means at least two recitations, or two or morerecitations). Furthermore, in those instances where a conventionanalogous to “at least one of A, B, and C, etc.” is used, in generalsuch a construction is intended in the sense one having skill in the artwould understand the convention (e.g., “a system having at least one ofA, B, and C” would include but not be limited to systems that have Aalone, B alone, C alone, A and B together, A and C together, B and Ctogether, and/or A, B, and C together, etc.). In those instances where aconvention analogous to “at least one of A, B, or C, etc.” is used, ingeneral such a construction is intended in the sense one having skill inthe art would understand the convention (e.g., “a system having at leastone of A, B, or C” would include but not be limited to systems that haveA alone, B alone, C alone, A and B together, A and C together, B and Ctogether, and/or A, B, and C together, etc.). It will be furtherunderstood by those within the art that typically a disjunctive wordand/or phrase presenting two or more alternative terms, whether in thedescription, claims, or drawings, should be understood to contemplatethe possibilities of including one of the terms, either of the terms, orboth terms unless context dictates otherwise. For example, the phrase “Aor B” will be typically understood to include the possibilities of “A”or “B” or “A and B.”

With respect to the appended claims, those skilled in the art willappreciate that recited operations therein may generally be performed inany order. Also, although various operational flow diagrams arepresented in a sequence(s), it should be understood that the variousoperations may be performed in other orders than those which areillustrated, or may be performed concurrently. Examples of suchalternate orderings may include overlapping, interleaved, interrupted,reordered, incremental, preparatory, supplemental, simultaneous,reverse, or other variant orderings, unless context dictates otherwise.Furthermore, terms like “responsive to,” “related to,” or otherpast-tense adjectives are generally not intended to exclude suchvariants, unless context dictates otherwise.

It is worthy to note that any reference to “one aspect,” “an aspect,”“an exemplification,” “one exemplification,” and the like means that aparticular feature, structure, or characteristic described in connectionwith the aspect is included in at least one aspect. Thus, appearances ofthe phrases “in one aspect,” “in an aspect,” “in an exemplification,”and “in one exemplification” in various places throughout thespecification are not necessarily all referring to the same aspect.Furthermore, the particular features, structures or characteristics maybe combined in any suitable manner in one or more aspects.

Any patent application, patent, non-patent publication, or otherdisclosure material referred to in this specification and/or listed inany Application Data Sheet is incorporated by reference herein, to theextent that the incorporated materials is not inconsistent herewith. Assuch, and to the extent necessary, the disclosure as explicitly setforth herein supersedes any conflicting material incorporated herein byreference. Any material, or portion thereof, that is said to beincorporated by reference herein, but which conflicts with existingdefinitions, statements, or other disclosure material set forth hereinwill only be incorporated to the extent that no conflict arises betweenthat incorporated material and the existing disclosure material.

In summary, numerous benefits have been described which result fromemploying the concepts described herein. The foregoing description ofthe one or more forms has been presented for purposes of illustrationand description. It is not intended to be exhaustive or limiting to theprecise form disclosed. Modifications or variations are possible inlight of the above teachings. The one or more forms were chosen anddescribed in order to illustrate principles and practical application tothereby enable one of ordinary skill in the art to utilize the variousforms and with various modifications as are suited to the particular usecontemplated. It is intended that the claims submitted herewith definethe overall scope.

What is claimed is:
 1. A method of assembling a backplane connectorsubassembly for a module of a modular energy system, wherein thebackplane connector subassembly physically and electrically connects atleast two modules stacked on top of one another, the method comprising:providing a back panel defining an inner surface; attaching a firstsupport member to the inner surface of the back panel, wherein the firstsupport member is configured to support an upstream connector; attachinga second support member to the inner surface of the back panel, whereinthe second support member is configured to support a downstreamconnector; attaching the upstream connector to the back panel by slidinga first mating hole defined in the upstream connector onto the firstsupport member; and attaching the downstream connector to the back panelby a sliding a second mating hole defined in the downstream connectoronto the second support member.
 2. The method of claim 1, furthercomprising attaching a support ledge to the inner surface of the backpanel between the first and second support members.
 3. The method ofclaim 2, wherein the upstream connector comprises a rib extending fromthe protrusion.
 4. The method of claim 3, further comprising resting therib of the upstream connector onto the support ledge.
 5. The method ofclaim 2, comprising attaching the support ledge offset from the firstsupport member.
 6. The method of claim 1, wherein the upstream connectorcomprises a protrusion that defines the first mating hole.
 7. The methodof claim 1, wherein the downstream connector comprises a protrusion thatdefines the second mating hole.
 8. A method of assembling a backplaneconnector subassembly for a module of a modular energy system, whereinthe backplane connector subassembly physically and electrically connectsat least two modules stacked on top of one another, the methodcomprising: providing a back panel defining an inner surface; attachinga first set of two support members to the inner surface of the backpanel, wherein the first set of two support members is configured tosupport an upstream connector; attaching a second set of two supportmembers to the inner surface of the back panel, wherein the second setof two support members is configured to support a downstream connector;attaching the upstream connector to the back panel by sliding first andsecond mating holes defined in the upstream connector onto the first setof two support members; and attaching the downstream connector to theback panel by a sliding first and second mating holes defined in thedownstream connector onto the second set of two support members.
 9. Themethod of claim 8, further comprising attaching a set of two supportledges to the inner surface of the back panel between the first set andthe second set of two support members.
 10. The method of claim 9,wherein the upstream connector comprises a first rib extending from thefirst protrusion and a second rib extending from the second protrusion.11. The method of claim 10, further comprising resting the first andsecond ribs of the upstream connector onto the set of two supportledges.
 12. The method of claim 8, comprising attaching the set of twosupport ledges offset from the first set of two support members.
 13. Themethod of claim 8, wherein the upstream connector comprises a firstprotrusion that defines the first mating hole and a second protrusionthat defines the second mating hole.
 14. The method of claim 8, whereinthe downstream connector comprises a first protrusion that defines thefirst mating hole and a second protrusion that defines the second matinghole.
 15. A method of assembling a display assembly for a header moduleof a modular energy system, the method comprising: providing a rearenclosure defining a recess and a plurality of notches; forming adisplay sub-assembly by coupling a touchscreen to a front cover, whereinthe front cover comprises a plurality of latches; and releasablycoupling the display sub-assembly to the rear enclosure by positioningthe plurality of latches of the front cover in the plurality of notchesof the rear enclosure.
 16. The method of claim 15, wherein the rearenclosure comprises a first electrical connector, wherein thetouchscreen comprises a second electrical connector, and wherein themethod further comprises electrically coupling the first electricalconnector to the second electrical connector.
 17. The method of claim15, further comprising coupling a latch mechanism to the rear enclosure,wherein the latch mechanism is configured to releasable couple thedisplay assembly to the header module.
 18. The method of claim 17,wherein coupling the latch mechanism to the rear enclosure comprises:positioning a slider bar in the recess; positioning a mounting plate inthe recess; coupling the mounting plate to the slider bar; and couplingthe mounting plate to the rear enclosure.
 19. The method of claim 18,wherein the mounting plate comprises a first aperture and a secondaperture, wherein the slider bar comprises a mounting hole and a pinextending therefrom, and wherein coupling the mounting plate to theslider bar comprising: positioning the pin in the first aperture;aligning the second aperture with the mounting hole; extending afastener through the second aperture and into the mounting hole; andcoupling the fastener to the mounting hole.
 20. The method of claim 17,wherein the rear enclosure further defines a first aperture and a secondaperture, wherein the latch mechanism comprises a first arm and a secondarm, and wherein the method further comprises extending the first armthrough the first aperture and extending the second arm through thesecond aperture.